Rubber tube extrusion process parameter optimization system

Abstract

The invention relates to the field of process control, and particularly discloses a rubber tube extrusion process parameter optimization system, which comprises an extrusion head design module, a process parameter optimization module and a real-time monitoring module, the extrusion head design module optimizes the flowing path and the material mixing effect by dividing a polymer flowing path into a plurality of layers; the technological parameter optimization module realizes real-time regulation and control on the thickness and the adhesive force of a rubber tube product by optimizing the temperature and the speed in the extrusion process; and the real-time monitoring module monitors the temperature change and pressure distribution of the polymer and the wall thickness of the rubber tube in real time by installing temperature, pressure and thickness sensors at an extrusion head and a screw outlet. By adopting the multi-layer flow channel design, the polymer flow path and the material mixing effect are optimized, and the uneven flow is reduced.

Description

Technical Field

[0001] The invention relates to the field of process control, and more specifically to a system for optimizing process parameters of hose extrusion. Background Art

[0002] Currently, a major challenge facing the hose extrusion process is how to effectively control the flow and heat distribution of the polymer in the extruder head to ensure the uniformity and stability of the extruded product. Traditional extruder head designs often have problems such as uneven flow of residual rubber and excessive temperature gradients, which can lead to unstable product quality and even defects such as cracks and bubbles.

[0003] In the existing public literature (Optimization Design of Hose Outer Rubber Layer Extruder Head [J]. Rubber Industry, 2016), an outer rubber layer extruder head is proposed, which consists of five parts: a back cover, a die transition part, a die fixture, a die and a heating ring. The back cover is provided with an inner liner, whose inner diameter is slightly larger than the outer diameter of the semi-finished rubber hose with a reinforcement layer. However, the inner liner is in direct contact with the semi-finished rubber hose, and is prone to wear during long-term use. After the inner liner is worn, it will affect its fixation and pressure relief effect on the hose, thereby affecting the uniformity of the thickness of the outer rubber layer. In the existing public patent (A Hard Core Hose Extrusion Mechanism, CN211807696U), a hard core hose extrusion mechanism is proposed, including an extruder barrel, an extruder head, an outer rubber extruder head and an inner core sleeve head. The outlet end of the inner core sleeve head has an extended nozzle extending to the outside of the outlet end of the outer rubber extruder head, which can support the formed hose and the tube core during extrusion to prevent the gap from changing and the hose from being eccentric due to gravity. However, the rubber is likely to remain inside the equipment during the extrusion process, and the cleaning of these residual rubber is difficult and requires a lot of time and manpower. Therefore, how to alleviate the uneven flow of residual rubber and achieve temperature zone control is a technical problem that needs to be solved urgently. Summary of the invention

[0004] In order to overcome the above-mentioned defects of the prior art, the present invention provides a hose extrusion process parameter optimization system, which optimizes the polymer flow path and material mixing effect and reduces uneven flow by adopting a multi-level flow channel design. The temperature of each area is adjusted by a temperature zoning control unit and the temperature and pressure balance is coordinated to achieve temperature zoning control. The speed unit is dynamically adjusted to adjust the hose thickness and adhesion in real time in combination with the relationship between the screw speed and the traction speed, so as to solve the problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A hose extrusion process parameter optimization system includes an extruder head design module, a process parameter optimization module and a real-time monitoring module; the extruder head design module optimizes the flow path and material mixing effect by dividing the polymer flow path into multiple levels, wherein the extruder head is composed of an inlet channel, a graduation channel, a distribution channel, a mold, a supplementary channel, a mold body, a mandrel torpedo and a mandrel; the process parameter optimization module optimizes the temperature and speed during the extrusion process to achieve real-time control of the thickness and adhesion of the hose product; the real-time monitoring module monitors the temperature change, pressure distribution and wall thickness of the polymer in real time; the real-time control of the thickness and adhesion of the hose product includes:

[0007] Step Z1, the thickness h(s) of the hose is affected by the screw speed and the pulling speed. The screw speed N s and traction speed N t There is a linear relationship between the changes in and the calculation formula is: Among them, h(s) is the thickness of the hose at time s, T(s) is the temperature in the flow channel at time s, P(s) is the flow channel pressure at time s, k1 is the influence of the screw speed and traction speed on the hose thickness, k2 is the influence of the flow channel temperature on the hose thickness, and k3 is the influence of the flow channel pressure on the hose thickness;

[0008] In step Z2, the adhesion force is also affected by the screw speed and the pulling speed. The adhesion force, the screw speed and the pulling speed are described by a nonlinear function: Among them, A(s) is the hose adhesion force at time s, k4 is the influence of screw speed and traction speed on the hose adhesion force, k5 is the influence of flow channel temperature on the hose adhesion force, and k6 is the influence of flow channel pressure on the hose adhesion force;

[0009] Step Z3, combining the feedback of temperature and pressure, dynamically adjust the screw speed and traction speed to achieve real-time control of the thickness and adhesion of the hose product: ΔN s (s)=k7·(Δh(s)+ΔA(s)),ΔN t (s)=k8·(Δh(s)+ΔA(s)), where ΔN s (s) is the adjustment amount of screw speed, ΔN t(s) is the adjustment amount of the traction speed, Δh(s) is the change in the thickness of the hose product, ΔA(s) is the change in the adhesion of the hose, k7 is the first gain coefficient, which indicates the response degree of the screw speed to the changes in the thickness and adhesion of the hose, and k8 is the second gain coefficient, which indicates the response degree of the traction speed to the changes in the thickness and adhesion of the hose. By real-time monitoring of the thickness h(s) and adhesion A(s) of the hose, the differences between them and the target values ​​are calculated, and the screw speed and traction speed are adjusted according to the differences, so that the thickness and adhesion of the hose can be restored to the ideal state in the shortest time.

[0010] As a further solution of the present invention, the extruder head design module optimizes the flow path and material mixing effect by dividing the polymer flow path into multiple levels, including the following specific contents: the polymer flowing into the extruder head through the inlet channel encounters the mandrel torpedo, which changes the polymer flow direction by 90 degrees, thereby radially directing the polymer to the outside, and during this flow process, the polymer fluid can be divided into many component flows through short cylindrical parallel distribution channels, the diameter of the distribution channels is 1 to 2.5 mm, and the distribution channels are arranged in the distribution sleeve perpendicular to the axis of the extruder head. After the polymer component flows through the distribution channels formed by the sleeve through holes, they enter the annular distribution channel and meet the conical surface of the inner wall of the extruder head body.

[0011] The extruder head adopts a multi-level flow channel design, which optimizes the flow path and improves the mixing effect of the material by dividing the polymer flow channel into multiple independent levels with different functions. The multi-level flow channel design achieves uniform distribution and effective mixing of the polymer through the configuration of flow channels at different levels. The design of the flow channel starts from the entrance of the extruder head and gradually transitions to the distribution and molding area. The extruder head includes an inlet flow channel and a distribution channel. Between the inlet flow channel and the distribution flow channel, the flow direction and flow rate of the polymer are optimized by designing multiple flow channel levels, thereby avoiding flow instability caused by uneven polymer flow rate or excessive friction resistance.

[0012] The polymer first enters the extruder head through the inlet flow channel. As the flow channel gradually narrows, the polymer flow rate accelerates, and at the same time, the distribution layer of the flow channel gradually spreads out, allowing the polymer fluid to flow smoothly in multiple distribution channels. Through the optimized layout of multiple distribution layer flow channels, the polymer can obtain stable pressure and uniform temperature distribution when flowing through each layer, which not only effectively reduces the occurrence of local overpressure or low pressure areas, but also avoids the unevenness of the product surface or structure by alleviating stress concentration caused by uneven pressure. The multi-level flow channel design structurally adopts multiple alternating levels of curved flow channels, so that the polymer can experience sufficient shearing during the flow process, thereby enhancing the mixing effect of the material. As the flow path of the polymer gradually changes, the components in the material are better evenly mixed. Especially when multiple polymers are co-extruded, the flow channel design ensures the full fusion of different polymers.

[0013] The multi-level flow channel design also has a temperature management function. During the extrusion process, temperature control is the key to ensure the smooth flow and molding of the polymer. The multi-level flow channel design configures independent temperature control devices for flow channels at different levels, so that the temperature of each flow channel area can be adjusted as needed, thereby avoiding polymer degradation and reduced production efficiency caused by uneven temperature.

[0014] As a further solution of the present invention, the process parameter optimization module realizes real-time control of the thickness and adhesion of the hose product by optimizing the temperature and speed during the extrusion process, including the following specific contents: the process parameter optimization module includes a temperature partition control unit and a dynamic speed adjustment unit, and the temperature partition control unit can not only adjust the temperature of each processing area, but also ensure the stability and consistency of the polymer in the entire extrusion process by optimizing the temperature gradient. The temperature of each area of ​​the extruder head is adjusted by an independent heating and cooling device. A higher temperature is required in the inlet area of ​​the extruder head to ensure that the polymer enters the flow channel smoothly and maintains good fluidity. A lower temperature is required in the distribution and molding area to avoid degradation or excessive plasticization caused by overheating of the material. A pressure sensor and a temperature sensor are set in each temperature control section to monitor and adjust the pressure and temperature of the fluid in real time. A collaborative control algorithm is used to balance the interaction between the temperature and pressure of the flow channel. The temperature data is collected in real time by the temperature sensor, and the pressure data is collected in real time by the pressure sensor. The following specific steps are included:

[0015] Step S1, there is a coupling relationship between the temperature and pressure of the flow channel. During the extrusion process, temperature and pressure jointly affect the fluidity of the polymer. The viscosity η(t) of the polymer is a function of the flow channel temperature T(t) and the flow channel pressure P(t), and the calculation formula is: Among them, η0 is the initial viscosity, B is the influence coefficient of temperature on viscosity, C is the influence coefficient of pressure on viscosity, T(t) is the instantaneous value of flow channel temperature, and P(t) is the instantaneous value of flow channel pressure. This formula shows that changes in flow channel temperature and pressure will affect the viscosity of the polymer, thereby affecting its fluidity; when the flow channel temperature increases, the viscosity decreases and the fluidity increases; and when the flow channel pressure increases, the viscosity increases and the fluidity decreases;

[0016] Step S2, monitoring the pressure change ΔP(t)=P(t)-P t , where ΔP(t) is the difference between the current pressure and the target pressure, P t is the target pressure value. If the pressure changes, the proportional control method is used to adjust the temperature according to the pressure change. The calculation formula of the proportional control method is: ΔT(t) = -K t ·ΔP(t), where ΔT(t) is the change in flow channel temperature, indicating the temperature change that needs to be adjusted, K t is the temperature adjustment gain coefficient; if the flow channel pressure P(t) increases, that is, ΔP(t)>0, the flow channel temperature will be lowered, that is, ΔT(t)<0, to avoid excessive viscosity of the polymer and ensure fluidity; if the flow channel pressure P(t) decreases, that is, ΔP(t)<0, the flow channel temperature will be increased, that is, ΔT(t)>0, to reduce the viscosity of the polymer and promote flow.

[0017] The dynamic speed adjustment unit combines the optimized relationship between the screw speed and the traction speed to adjust the thickness and adhesion of the hose product in real time. s Determines the output rate of the polymer, the pulling speed N t Affects the stretching degree and final thickness of the hose. As the screw speed increases, the extruded polymer flow rate increases and the polymer residence time in the flow channel decreases. At this time, if the pulling speed fails to keep up in time, it may lead to uneven hose wall thickness and even poor stretching; on the contrary, if the pulling speed is too fast, it may increase the surface roughness of the hose and even cause cracks or uneven adhesion. By establishing a speed adjustment model, the thickness and adhesion of the hose product can be controlled in real time.

[0018] As a further solution of the present invention, the real-time monitoring module monitors the temperature change, pressure distribution and wall thickness of the polymer in real time by installing temperature, pressure and thickness sensors at the extruder head and screw outlet, including the following specific contents: the extruder head and screw outlet are key areas in the polymer flow and molding process. The temperature sensor installed at the extruder head is used to monitor the temperature change of the polymer in real time, and the pressure sensor measures the pressure distribution during the extrusion process. At the same time, the thickness sensor installed at the screw outlet can detect the wall thickness of the hose in real time.

[0019] The technical effects and advantages of a hose extrusion process parameter optimization system of the present invention are as follows: the extruder head design module of the present invention adopts a multi-level flow channel design to optimize the polymer flow path and material mixing effect, reduce the problems of uneven flow, pressure concentration and uneven temperature, ensure product uniformity, and also have a temperature management function, which is beneficial to polymer molding; the process parameter optimization module adjusts the temperature of each area through a temperature partition control unit and coordinates the temperature and pressure balance, and the dynamic speed adjustment unit combines the relationship between the screw speed and the traction speed to regulate the thickness and adhesion of the hose in real time, effectively solving product defects caused by improper temperature and speed; the real-time monitoring module installs sensors in key areas to monitor temperature, pressure and wall thickness in real time, so as to facilitate timely detection of problems and adjustment of parameters. The present invention can effectively alleviate the uneven flow of residual rubber, realize temperature partition control, and improve the product quality and production efficiency of hose extrusion. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 The present invention is a schematic structural diagram of a system for optimizing process parameters of hose extrusion.

[0021] Figure 2 The present invention is a schematic structural diagram of an outer rubber layer extrusion die head in the prior art.

[0022] Figure 3 The present invention is a structural schematic diagram of a hard core hose extrusion mechanism in the prior art.

[0023] Figure 4 The present invention is a schematic diagram of the structure of an extrusion head in a system for optimizing process parameters of hose extrusion.

[0024] Figure 4 Middle: 1. Inlet channel; 2. Indexing channel; 3. Distribution channel; 4. Mold; 5. Supplementary channel; 6. Mold body; 7. Mandrel torpedo; 8. Mandrel; 9. Polymer flow direction. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] Example 1

[0027] See also Figure 1As shown in the structural schematic diagram, an embodiment of the present invention provides a hose extrusion process parameter optimization system, which includes an extruder head design module, a process parameter optimization module and a real-time monitoring module; the extruder head design module optimizes the flow path and material mixing effect by dividing the polymer flow path into multiple levels; the process parameter optimization module optimizes the temperature and speed during the extrusion process to achieve real-time regulation of the thickness and adhesion of the hose product; the real-time monitoring module monitors the temperature change, pressure distribution and hose wall thickness of the polymer in real time by installing temperature, pressure and thickness sensors at the extruder head and the screw outlet.

[0028] In this embodiment, see Figure 2 The structural diagram shown is a kind of outer rubber layer extruder head proposed in the prior art, which is composed of five parts: rear cover, die transition part, die fixture, die and heating ring. The rear cover is provided with an inner liner, whose inner diameter is slightly larger than the outer diameter of the semi-finished rubber hose with a reinforcement layer. However, the inner liner is in direct contact with the semi-finished rubber hose, which is easy to wear during long-term use. When the inner liner is worn, it will affect its fixing and pressure relief function on the rubber hose, thereby affecting the uniformity of the thickness of the outer rubber layer. Figure 3 The structural schematic diagram shown is a hard core hose extrusion mechanism proposed in the prior art, including an extruder barrel, an extruder head, an outer rubber extrusion head and an inner core sleeve head. The outlet end of the inner core sleeve head has an extended nozzle extending to the outside of the outlet end of the outer rubber extrusion head, which can support the formed hose and the tube core during extrusion to prevent the gap from changing and the hose from being eccentric due to gravity. However, the rubber is likely to remain inside the equipment during the extrusion process, and the cleaning of these residual rubber materials is difficult and requires more time and manpower.

[0029] In this embodiment, see Figure 4 The structural schematic diagram shown is the extrusion head proposed by the present invention, which consists of an inlet channel 1, a dividing channel 2, a distribution channel 3, a mold 4, a supplementary channel 5, a mold body 6, a mandrel torpedo 7, a mandrel 8, and a polymer flow direction 9.

[0030] Furthermore, the extruder head design module optimizes the flow path and material mixing effect by dividing the polymer flow path into multiple levels, including: the polymer flowing into the extruder head through the inlet channel encounters the mandrel torpedo, which changes the polymer flow direction by 90 degrees, thereby radially directing the polymer to the outside, and during this flow process, the polymer fluid can be divided into many component flows through short cylindrical parallel distribution channels, the diameter of the distribution channels is 1 to 2.5 mm, and the distribution channels are arranged in the distribution sleeve perpendicular to the axis of the extruder head. After the polymer component flows through the distribution channels formed by the sleeve through holes, they enter the annular distribution channel and meet the conical surface of the inner wall of the extruder head body.

[0031] The extruder head adopts a multi-level flow channel design, which optimizes the flow path and improves the mixing effect of the material by dividing the polymer flow channel into multiple independent levels with different functions. The multi-level flow channel design achieves uniform distribution and effective mixing of the polymer through the configuration of flow channels at different levels. The design of the flow channel starts from the entrance of the extruder head and gradually transitions to the distribution and molding area. The extruder head includes an inlet flow channel and a distribution channel. Between the inlet flow channel and the distribution flow channel, the flow direction and flow rate of the polymer are optimized by designing multiple flow channel levels, thereby avoiding flow instability caused by uneven polymer flow rate or excessive friction resistance.

[0032] The polymer first enters the extruder head through the inlet flow channel. As the flow channel gradually narrows, the polymer flow rate accelerates, and at the same time, the distribution layer of the flow channel gradually spreads out, allowing the polymer fluid to flow smoothly in multiple distribution channels. Through the optimized layout of multiple distribution layer flow channels, the polymer can obtain stable pressure and uniform temperature distribution when flowing through each layer, which not only effectively reduces the occurrence of local overpressure or low pressure areas, but also avoids the unevenness of the product surface or structure by alleviating stress concentration caused by uneven pressure. The multi-level flow channel design structurally adopts multiple alternating levels of curved flow channels, so that the polymer can experience sufficient shearing during the flow process, thereby enhancing the mixing effect of the material. As the flow path of the polymer gradually changes, the components in the material are better evenly mixed. Especially when multiple polymers are co-extruded, the flow channel design ensures the full fusion of different polymers.

[0033] The multi-level flow channel design also has a temperature management function. During the extrusion process, temperature control is the key to ensure the smooth flow and molding of the polymer. The multi-level flow channel design configures independent temperature control devices for flow channels at different levels, so that the temperature of each flow channel area can be adjusted as needed, thereby avoiding polymer degradation and reduced production efficiency caused by uneven temperature. For example, the distribution layer flow channel of the extruder head can use a lower temperature to maintain the plasticity of the polymer, while the molding layer flow channel requires a higher temperature to ensure the fluidity and molding effect of the polymer.

[0034] Furthermore, the process parameter optimization module realizes real-time control of the thickness and adhesion of the hose product by optimizing the temperature and speed during the extrusion process, including: the process parameter optimization module includes a temperature partition control unit and a dynamic speed adjustment unit, and the temperature partition control unit can not only adjust the temperature of each processing area, but also ensure the stability and consistency of the polymer throughout the extrusion process by optimizing the temperature gradient. The temperature of each area of ​​the extruder head is adjusted by an independent heating and cooling device. A higher temperature is required in the inlet area of ​​the extruder head to ensure that the polymer enters the flow channel smoothly and maintains good fluidity. A lower temperature is required in the distribution and molding area to avoid degradation or excessive plasticization caused by overheating of the material. A pressure sensor and a temperature sensor are set in each temperature control section to monitor and adjust the pressure and temperature of the fluid in real time. A collaborative control algorithm is used to balance the interaction between the temperature and pressure of the flow channel. The temperature data is collected in real time through the temperature sensor, and the pressure data is collected in real time through the pressure sensor. The following specific steps are included:

[0035] Step S1, there is a coupling relationship between the temperature and pressure of the flow channel. During the extrusion process, temperature and pressure jointly affect the fluidity of the polymer. The viscosity η(t) of the polymer is a function of the flow channel temperature T(t) and the flow channel pressure P(t), and the calculation formula is: Among them, η0 is the initial viscosity, B is the influence coefficient of temperature on viscosity, C is the influence coefficient of pressure on viscosity, T(t) is the instantaneous value of flow channel temperature, and P(t) is the instantaneous value of flow channel pressure. This formula shows that changes in flow channel temperature and pressure will affect the viscosity of the polymer, thereby affecting its fluidity; when the flow channel temperature increases, the viscosity decreases and the fluidity increases; and when the flow channel pressure increases, the viscosity increases and the fluidity decreases;

[0036] Step S2, monitoring the pressure change ΔP(t)=P(t)-P t , where ΔP(t) is the difference between the current pressure and the target pressure, P t is the target pressure value. If the pressure changes, the proportional control method is used to adjust the temperature according to the pressure change. The calculation formula of the proportional control method is: ΔT(t) = -K t ·ΔP(t), where ΔT(t) is the change in flow channel temperature, indicating the temperature change that needs to be adjusted, K t is the temperature adjustment gain coefficient; if the flow channel pressure P(t) increases, that is, ΔP(t)>0, the flow channel temperature will be lowered, that is, ΔT(t)<0, to avoid excessive viscosity of the polymer and ensure fluidity; if the flow channel pressure P(t) decreases, that is, ΔP(t)<0, the flow channel temperature will be increased, that is, ΔT(t)>0, to reduce the viscosity of the polymer and promote flow.

[0037] The dynamic speed adjustment unit combines the optimized relationship between the screw speed and the traction speed to adjust the thickness and adhesion of the hose product in real time. s Determines the output rate of the polymer, the pulling speed N t Affects the stretching degree and final thickness of the hose. As the screw speed increases, the extruded polymer flow rate increases and the polymer residence time in the flow channel decreases. At this time, if the pulling speed fails to keep up in time, it may lead to uneven hose wall thickness and even poor stretching; conversely, if the pulling speed is too fast, it may increase the surface roughness of the hose and even cause cracks or uneven adhesion. Therefore, by establishing a speed adjustment model, real-time regulation of the thickness and adhesion of the hose product is achieved. The speed adjustment model includes the following steps:

[0038] Step Z1, the thickness h(s) of the hose is affected by the screw speed and the pulling speed. The screw speed N s and traction speed N t There is a linear relationship between the changes in and the calculation formula is: Among them, h(s) is the thickness of the hose at time s, T(s) is the temperature in the flow channel at time s, P(s) is the flow channel pressure at time s, k1 is the influence of the screw speed and traction speed on the hose thickness, k2 is the influence of the flow channel temperature on the hose thickness, and k3 is the influence of the flow channel pressure on the hose thickness;

[0039] In step Z2, the adhesion force is also affected by the screw speed and the pulling speed. The adhesion force, the screw speed and the pulling speed are described by a nonlinear function: Among them, A(s) is the hose adhesion force at time s, k4 is the influence of screw speed and traction speed on the hose adhesion force, k5 is the influence of flow channel temperature on the hose adhesion force, and k6 is the influence of flow channel pressure on the hose adhesion force;

[0040] Step Z3, combining the feedback of temperature and pressure, dynamically adjust the screw speed and traction speed to achieve real-time control of the thickness and adhesion of the hose product: ΔN s (s)=k7·(Δk(s)+ΔA(s)),ΔN t (s)=k8·(Δh(s)+ΔA(s)), where ΔN s (s) is the adjustment amount of screw speed, ΔN t(s) is the adjustment amount of the traction speed, Δh(s) is the change in the thickness of the hose product, ΔA(s) is the change in the adhesion of the hose, k7 is the first gain coefficient, which indicates the response degree of the screw speed to the changes in the thickness and adhesion of the hose, and k8 is the second gain coefficient, which indicates the response degree of the traction speed to the changes in the thickness and adhesion of the hose. By real-time monitoring of the thickness h(s) and adhesion A(s) of the hose, the differences between them and the target values ​​are calculated, and the screw speed and traction speed are adjusted according to the differences, so that the thickness and adhesion of the hose can be restored to the ideal state in the shortest time.

[0041] Furthermore, the real-time monitoring module monitors the temperature change, pressure distribution and wall thickness of the polymer in real time by installing temperature, pressure and thickness sensors at the extruder head and screw outlet, including: the extruder head and screw outlet are key areas in the polymer flow and molding process, the temperature sensor installed at the extruder head is used to monitor the temperature change of the polymer in real time, and the pressure sensor measures the pressure distribution during the extrusion process. At the same time, the thickness sensor installed at the screw outlet can detect the wall thickness of the hose in real time.

[0042] In this embodiment, the process parameter optimization module is connected to the extrusion head design module, and the real-time monitoring module is connected to the process parameter optimization module.

[0043] The extruder design module of the present invention adopts a multi-level flow channel design to optimize the polymer flow path and material mixing effect, reduce the problems of uneven flow, pressure concentration and uneven temperature, ensure product uniformity, and also have a temperature management function, which is conducive to polymer molding; the process parameter optimization module adjusts the temperature of each area through the temperature partition control unit and coordinates the temperature and pressure balance. The dynamic speed adjustment unit combines the relationship between the screw speed and the traction speed to regulate the thickness and adhesion of the hose in real time, effectively solving product defects caused by improper temperature and speed; the real-time monitoring module installs sensors in key areas to monitor temperature, pressure and wall thickness in real time, so as to facilitate timely detection of problems and adjustment of parameters. The present invention can effectively alleviate the uneven flow of residual rubber, realize temperature partition control, and improve the product quality and production efficiency of hose extrusion.

[0044] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

[0045] Finally: 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 spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A hose extrusion process parameter optimization system, characterized in that: The invention comprises an extruder head design module, a process parameter optimization module and a real-time monitoring module; the extruder head design module optimizes the flow path and material mixing effect by dividing the polymer flow path into multiple levels, wherein the extruder head is composed of an inlet channel (1), a graduation channel (2), a distribution channel (3), a mold (4), a supplementary channel (5), a mold body (6), a mandrel torpedo (7) and a mandrel (8); the process parameter optimization module realizes real-time control of the thickness and adhesion of the hose product by optimizing the temperature and speed during the extrusion process; The real-time monitoring module monitors the temperature change, pressure distribution and wall thickness of the polymer in real time; the real-time regulation of the thickness and adhesion of the hose product includes: Combined with the feedback of temperature and pressure, the screw speed and traction speed are dynamically adjusted to achieve real-time control of the thickness and adhesion of the hose product: ΔN s (s)=k7·(Δh(s)+ΔA(s)),ΔN t (s)=k8·(Δh(s)+Δa(s)), where ΔN s (s) is the adjustment amount of screw speed, ΔN t (s) is the adjustment amount of the traction speed, Δh(s) is the change in the thickness of the hose product, ΔA(s) is the change in the adhesion of the hose, k7 is the first gain coefficient, which indicates the response degree of the screw speed to the changes in the thickness and adhesion of the hose, and k8 is the second gain coefficient, which indicates the response degree of the traction speed to the changes in the thickness and adhesion of the hose.

2. A hose extrusion process parameter optimization system according to claim 1, characterized in that In the process parameter optimization module, a pressure sensor and a temperature sensor are set in each temperature control section to monitor and adjust the pressure and temperature of the fluid in real time. A collaborative control algorithm is used to balance the interaction between the temperature and pressure of the flow channel. The temperature data is collected in real time through the temperature sensor, and the pressure data is collected in real time through the pressure sensor. The specific steps are as follows: Step S1, there is a coupling relationship between the temperature and pressure of the flow channel. During the extrusion process, temperature and pressure jointly affect the fluidity of the polymer. The viscosity η(t) of the polymer is a function of the flow channel temperature T(t) and the flow channel pressure P(t), and the calculation formula is: Among them, η0 is the initial viscosity, B is the influence coefficient of temperature on viscosity, C is the influence coefficient of pressure on viscosity, T(t) is the instantaneous value of flow channel temperature, and P(t) is the instantaneous value of flow channel pressure. This formula shows that changes in flow channel temperature and pressure will affect the viscosity of the polymer, thereby affecting its fluidity; when the flow channel temperature increases, the viscosity decreases and the fluidity increases; and when the flow channel pressure increases, the viscosity increases and the fluidity decreases; Step S2, monitoring the pressure change ΔP(t)=P(t)-P t , where ΔP(t) is the difference between the current pressure and the target pressure, P t is the target pressure value. If the pressure changes, the proportional control method is used to adjust the temperature according to the pressure change. The calculation formula of the proportional control method is: ΔT(t) = -K t ·ΔP(t), where ΔT(t) is the change in flow channel temperature, indicating the temperature change that needs to be adjusted, K t is the temperature adjustment gain coefficient; if the flow channel pressure P(t) increases, that is, ΔP(t)>0, the flow channel temperature will be lowered, that is, ΔT(t)<0, to avoid excessive viscosity of the polymer and ensure fluidity; if the flow channel pressure P(t) decreases, that is, ΔP(t)<0, the flow channel temperature will be increased, that is, ΔT(t)>0, to reduce the viscosity of the polymer and promote flow.

3. A hose extrusion process parameter optimization system according to claim 1, characterized in that The extruder head divides the polymer flow channel into independent and functionally different levels, gradually transitioning from the inlet flow channel to the distribution and molding area, optimizing the flow path and material mixing effect, and avoiding flow instability caused by uneven flow rate and friction resistance.

4. The hose extrusion process parameter optimization system according to claim 1, characterized in that: The multi-layer flow channel enables the polymer to obtain stable pressure and uniform temperature distribution when flowing through the flow channels of each distribution layer, reduces local overpressure or low pressure areas and stress concentration, avoids product unevenness, and uses alternating layers of curved flow channels to enhance the material mixing effect, ensuring full fusion of multiple polymers during co-extrusion.

5. The hose extrusion process parameter optimization system according to claim 1, characterized in that The multi-layer flow channel has a temperature management function. Independent temperature control devices are configured for flow channels at different levels to adjust the temperature of each area according to needs. For example, the distribution layer flow channel adopts a lower temperature to maintain plasticity, and the molding layer flow channel adopts a high temperature to ensure fluidity and molding effect.

6. The hose extrusion process parameter optimization system according to claim 1, characterized in that The process parameter optimization module includes a temperature partition control unit and a dynamic speed adjustment unit. The temperature partition control unit adjusts the temperature of the processing area and optimizes the temperature gradient to ensure the stability and consistency of the polymer extrusion process. In the temperature partition control unit, the temperature of each area of ​​the extruder head is adjusted by an independent heating and cooling device. The high temperature in the inlet area ensures that the polymer enters the flow channel and maintains fluidity. The low temperature in the distribution and molding area avoids overheating degradation or excessive plasticization of the material. Pressure and temperature sensors are set in the temperature control section to monitor and adjust the fluid pressure and temperature in real time.

7. The hose extrusion process parameter optimization system according to claim 1, characterized in that The dynamic speed adjustment unit combines the optimization relationship between the screw speed and the pulling speed to adjust the thickness and adhesion of the hose product in real time. The screw speed determines the polymer output rate, and the pulling speed affects the stretching degree and final thickness of the hose.

8. The hose extrusion process parameter optimization system according to claim 1, characterized in that ,The real-time monitoring module installs temperature and pressure sensors at the extrusion head to monitor the temperature change and pressure distribution of the polymer, and installs a thickness sensor at the screw outlet to detect the wall thickness of the hose.

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