High-speed surface material scanning detection control system and signal processing method thereof

Abstract

The invention relates to the technical field of industrial detection, and discloses a high-speed surface material scanning detection control system which comprises an HMI module used for inputting target parameters by an operator and displaying quantitative data, moisture data, thickness data, historical curves and process parameter adjustment of materials in real time; the PLC control module is connected with the HMI module and used for receiving the target parameters and sensor detection data; the invention further discloses a high-speed surface material scanning detection control signal processing method which comprises the following steps: S1, an operator inputs target parameters through the HMI module, and the target parameters comprise a target quantitative value, a moisture value and a thickness value of the material; by optimizing the structural design and the dynamic control algorithm, the problems of beam deformation, desynchrony of the upper probe and the lower probe, insufficient multi-dimensional parameter detection precision and control response lag in large-width detection are solved, high-precision detection, synchronous acquisition and closed-loop control are realized, and the stability and the real-time performance of the system are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial detection, and in particular to a high-speed surface material scanning detection control system and a signal processing method thereof. Background Art

[0002] The width materials (such as paper, film, non-woven fabrics, etc.) on high-speed production lines are widely used in packaging, electronics, energy and other industries. Their quality stability directly affects the performance and market competitiveness of downstream products. In the production process, as the width of the width materials gradually expands (such as 2000mm to 10000mm) and the speed of the production line continues to increase (300m / min to 1800m / min), the online detection of material quality has higher requirements for accuracy, real-time and stability. Traditional detection systems have gradually exposed certain technical deficiencies in these application scenarios and are difficult to meet actual needs.

[0003] For paper materials, grammage (weight per unit area), moisture content and ash content (inorganic content) are important indicators that affect their printability and mechanical strength; the thickness uniformity of film materials is directly related to their optical and mechanical properties; non-woven fabrics require precise detection of quantitative and moisture indicators to ensure production quality. However, in actual testing, as the width of the material increases, the structural stability of the testing equipment begins to be challenged. For example, the traditional single-beam design is difficult to cope with the deformation problem caused by a large span (such as 10,000 mm), which may cause the scanning path to deviate, resulting in a decrease in detection accuracy, or even missing quality problems in key areas.

[0004] In addition, in high-speed production lines, the movement speed of the web material is extremely high, which places stringent requirements on the response speed and synchronous control of the detection equipment. In particular, in scanning detection devices, the upper and lower probes need to be precisely synchronized to ensure the synchronous collection of physical parameters (such as thickness, basis weight, moisture, etc.) on the upper and lower surfaces of the material. However, in existing detection technologies, the upper and lower probes often cause trajectory deviation or detection delay due to the non-synchronization of the drive system or errors in the transmission mechanism, which leads to inconsistent parameter collection and affects the reliability of the overall detection results.

[0005] On the other hand, current technology also has certain limitations in the signal processing methods of the detection system. For example, multiple parameters (such as weight, moisture, thickness) need to be collected and processed at the same time, which requires the system to have the ability to quickly process multi-dimensional data. However, in traditional signal processing systems, due to the lag of analog-to-digital conversion and deviation calculation, it is difficult to optimize the control signal of the execution equipment in real time under high-speed production conditions, which further amplifies the time lag problem between detection and adjustment and cannot effectively achieve closed-loop control. Summary of the invention

[0006] In view of the shortcomings of the prior art, the present invention provides a high-speed surface material scanning detection control system and a signal processing method thereof, which solves the problems of inaccurate closed-loop control caused by insufficient detection accuracy, poor structural stability, asynchrony of upper and lower probes and signal processing lag in the production process of high-speed and large-width surface materials.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: a high-speed surface material scanning detection control system, comprising: HMI module, which is used by the operator to input target parameters and display the quantitative data, moisture data, thickness data, historical curves and process parameter adjustments of the material in real time; A PLC control module, connected to the HMI module, for receiving the target parameters and sensor detection data, performing signal processing, deviation calculation and outputting control signals; A scanning control module is used to drive the scanning detection device to achieve full coverage scanning of the material surface; Sensor module, used to collect the unit area weight, thickness and humidity of the material; Execution equipment module, used to adjust the moisture, concentration, pressure and conveying speed of the material; Compensation algorithm module, used to dynamically correct the control signal according to the deviation of the material's physical parameters; The signal feedback module is connected to the sensor module and the PLC control module, and is used for collecting the adjusted material parameters in real time and updating the control signal.

[0008] Preferably, the scanning detection device comprises: Two cabinets, two beams are connected between the two cabinets, screw rods are arranged inside the two beams, one end of the two screw rods are connected to pulleys, the two pulleys are connected by a belt 6, the outer wall of the top screw rod is threadedly connected to the movable seat 2, and the outer wall of the bottom screw rod is threadedly connected to the movable seat 1, and detection machines are installed on the opposite sides of the movable seat 1 and the movable seat 2.

[0009] Preferably, the scanning control module includes: A servo motor is installed at the end of the screw rod at the bottom, and is used to drive the scanning detection device to achieve full coverage scanning of the material surface; A position encoder installed in the detection machine for real-time monitoring and correction of the operating position of the scanning detection device; The scanning path calibration unit is used to adjust the scanning trajectory of the scanning detection device in real time according to the position information fed back by the position encoder.

[0010] Preferably, the execution device module includes: Humidifier, used to increase and regulate the moisture content of materials; Dryer, used to reduce the moisture content of materials; Pressure regulating valve is used to adjust the fluid pressure during material transportation.

[0011] Preferably, the PLC control module includes: A data acquisition unit, used for performing analog-to-digital conversion and filtering processing on the analog signals collected by the sensor; A deviation calculation unit, used for calculating the deviation between the set target value and the actual detection value; The signal output unit is used to generate a dynamic control signal according to the deviation.

[0012] Preferably, the compensation algorithm module includes: A quantitative compensation unit is used to adjust the material conveying speed according to the deviation of the material weight per unit area; Thickness compensation unit, used to adjust the roller pressure according to the deviation of material thickness; Moisture compensation unit, used to adjust the operating parameters of the humidifier or dryer according to the deviation of material humidity.

[0013] Preferably, the sensor module comprises: A quantitative sensor, which is installed in the detection machine and is used to collect the unit area weight of the material; Thickness sensor, which is installed in the detection machine to measure the thickness of the material; Moisture sensor, which is installed in the detection machine and is used to detect the moisture content of the material; The spectral analysis sensor is installed in the detection machine to detect the chemical composition or inorganic content on the surface of the material, and combines the signal processing function of the PLC control module to realize real-time analysis of chemical parameters.

[0014] A method for processing control signals for high-speed surface material scanning detection comprises the following steps: S1. The operator inputs the target parameters, including the target quantitative value, moisture value and thickness value of the material through the HMI module; S2, start the scanning control module, and drive the scanning detection device through the servo motor 4 to achieve full coverage scanning of the material surface; S3, collecting the unit area weight, thickness and humidity data of the material through the sensor module; S4, performing analog-to-digital conversion and filtering processing on the collected analog signal through the PLC control module; S5. Calculate the deviation between the target parameter and the actual detection value and identify the adjustment requirement; S6. Dynamically generate an optimized control signal through a compensation algorithm module according to the deviation value; S7, output control signals to the execution equipment module to adjust the moisture, concentration, thickness and conveying speed of the material; S8, enable the signal feedback module, collect the adjusted material parameters in real time, and input the feedback information into the PLC control module for updating; S9. Form a closed-loop control logic to make the material parameters continuously approach the target value.

[0015] The present invention provides a high-speed surface material scanning detection control system and a signal processing method thereof. It has the following beneficial effects: 1. The present invention adopts the technical solution of "double beam structure combined with synchronous screw drive". By arranging an upper and lower double beam between the two cabinets, the built-in screw and pulley realize synchronous drive, thereby enhancing the structural stability of the beam and avoiding the deformation problem of a single beam due to excessive span in the detection of large-width materials. The technical effect of improving the operating accuracy of the detection device and the deformation resistance of the beam is achieved. Compared with the technical solution in the prior art that the single beam design is prone to deformation in a large-width scenario and leads to a decrease in detection accuracy, the problem of insufficient beam rigidity in large-width detection is solved.

[0016] 2. The present invention adopts the technical solution of "symmetrical arrangement of upper and lower probes combined with synchronous drive of double screws". The upper and lower detection machines are precisely synchronized through the top and bottom screw drives respectively. The motion trajectory is dynamically corrected with the position information fed back in real time by the position encoder, thereby achieving the technical effect of highly consistent operation of the upper and lower probes and precise synchronization of data acquisition. Compared with the problems of large detection errors and material parameter deviations caused by inconsistent operation of the upper and lower probes in the prior art, this solves the problem that the upper and lower probes cannot operate synchronously during high-speed movement.

[0017] 3. The present invention adopts the technical solution of "upper and lower distribution design of sensor modules and coordinated acquisition of multiple parameters", combined with the dynamic correction of real-time data by the compensation algorithm module, which significantly improves the detection accuracy of material quantity, moisture and thickness, and achieves the technical effect of combining real-time detection with precise control. Compared with the technical solution of only detecting a single parameter or dynamically controlling the response delay in the prior art, it solves the problem of multi-dimensional real-time acquisition and dynamic adjustment of complex material parameters in high-speed detection scenarios.

[0018] 4. The present invention adopts the control method of "deviation calculation combined with dynamic compensation algorithm". By real-time collection of material quantity, moisture and thickness data, it generates dynamically optimized control signals and accurately adjusts the execution equipment modules, thereby achieving the technical effect of closed-loop control of material parameters. Compared with the technical solutions in the prior art with lagging control methods and low deviation compensation efficiency, it solves the problem that dynamic fluctuations of material parameters are difficult to respond to and adjust in real time, and improves the stability and control accuracy of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a system framework diagram of the present invention; Figure 2 It is a three-dimensional diagram of the scanning detection device of the present invention; Figure 3 A bottom view of the scanning detection device of the present invention; Figure 4 It is a framework diagram of the scanning control module of the present invention; Figure 5 It is a module framework diagram of the execution device of the present invention; Figure 6 It is a PLC control module framework diagram of the present invention; Figure 7 It is a compensation algorithm module framework diagram of the present invention; Figure 8 It is a sensor module framework diagram of the present invention; Fig. 9 is a flow chart of the control signal processing method of the present invention; Fig.10 It is a logic diagram of the control signal processing method of the present invention; Fig.11 for Fig.10 The logic diagram at A in the middle; Fig.12 for Fig.10 Logic diagram at B in the figure.

[0020] Among them, 1. cabinet; 2. beam; 3. screw; 4. servo motor; 5. pulley; 6. belt; 7. moving seat 1; 8. moving seat 2; 9. detection machine; 10. position encoder; 11. quantitative sensor; 12. thickness sensor; 13. moisture sensor; 14. spectral analysis sensor. DETAILED DESCRIPTION

[0021] The following will be combined with the drawings in the specification 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.

[0022] Please see attached Figure 1 The embodiment of the present invention provides a high-speed surface material scanning detection control system, comprising: HMI module, which is used by the operator to input target parameters and display the quantitative data, moisture data, thickness data, historical curves and process parameter adjustments of the material in real time; The HMI module is a key human-machine interaction component that runs through the entire system operation and monitoring process. In the system control process, the HMI module not only provides an interface for operators to input target parameters, but also a platform for real-time reflection of material status and test data. Through the HMI module, operators can monitor the quantitative data, moisture data, thickness data, historical curves and the effects of adjusting process parameters of materials at any time. This module plays a bridging role in the operation of the entire system, combining operating instructions with the dynamic feedback of the detection system, so as to achieve precise adjustment of material parameters.

[0023] In this embodiment, the HMI module is used to receive the target parameters set by the operator. The target parameters usually include the target values ​​of the material's unit area weight, thickness, and moisture. These target values ​​are sent to the PLC module as the reference values ​​for subsequent deviation calculation and compensation. The HMI module can also provide an intuitive interface for the operator to view in real time whether the set values ​​are correctly transmitted and applied to the system.

[0024] Specifically, the HMI module has a user-friendly interface. In the interface, the setting items of the target parameters include quantitative target values , Thickness target value and moisture target These parameters can be adjusted through sliders, value input boxes or drop-down menus. In general, the HMI module will perform a legality check on the input target value, such as whether the value range meets production requirements to avoid incorrect input.

[0025] In this embodiment, the HMI module can also display the real-time detection data fed back from the sensor module. These data include: Actual quantitative value of the material ; Real-time thickness of the material ; Real-time detection of material moisture value .

[0026] As an option, the HMI module displays the dynamic trend of parameters through a curve chart of historical data. In the curve chart, the vertical axis is the detection value and the horizontal axis is the time axis. The system automatically generates sampling points per second and connects them into a curve, which is convenient for operators to intuitively understand the changes in material parameters.

[0027] In one possible implementation, the HMI module can replay the historical curve in segments. For example, the operator can select a certain time interval and look back to view the parameter changes within the corresponding time to analyze whether the system operation is stable. These functions provide an intuitive reference for subsequent process adjustments.

[0028] In this embodiment, the HMI module also supports exporting parameter data in the form of reports. In some embodiments, the report content may include target parameters, actual detection values, deviation values, and changes in adjustment signals. For example, an operator can export adjustment records within a day and analyze the correlation between adjustment signals and detection data.

[0029] As an option, the HMI module can also display the intermediate results of the deviation calculation. In the deviation calculation, the core formula of the system calculation is: e=r-y, where: e is the deviation value; r is the target value obtained from the HMI input; y is the actual detection value obtained from the sensor module feedback.

[0030] The HMI module displays the real-time deviation value graphically, allowing the operator to quickly determine whether the deviation exceeds the allowable range. If the deviation exceeds the set threshold, the HMI module will display a red warning prompt to prompt the operator to intervene or optimize the target parameter setting.

[0031] In a possible implementation, the HMI module can also adjust the control strategy. For example, when the operator finds that the moisture value of the material detected in real time is When the fluctuation is large, the control algorithm mode can be directly switched through the HMI. After switching, the PLC control module can switch from proportional control mode to PID control mode to achieve more accurate compensation signal generation.

[0032] Generally, the HMI module also has a self-diagnosis function. When a detection device, sensor module, or actuator module fails, the HMI module will display the fault status, specifically indicate the module where the problem is located, and upload the diagnostic report to the central control system. In some embodiments, the HMI module will display the priority based on the severity of the problem. For example, abnormal movement of a servo motor will be marked as a high priority problem and trigger the system emergency stop function.

[0033] In this embodiment, the HMI module also has a permission management function. The operator needs to log in through an account to adjust the target parameters, and users with different permission levels can access different operations. For example, ordinary operators can only adjust the target parameters, while advanced users can adjust the key coefficients of the compensation algorithm.

[0034] Specifically, the HMI module can also be implemented in a variety of hardware forms. In some embodiments, the HMI module is integrated on the device console in the form of a touch screen. In other embodiments, the HMI module is connected via a network and runs on a computer, tablet or smart phone in the form of remote control.

[0035] In another possible implementation, the HMI module can be combined with a position encoder to display the position information of the scanning device in real time. It will be displayed as a dynamic slider on the interface, allowing operators to monitor the progress of scanning coverage.

[0036] Please see attached Figure 6 ,The PLC control module is connected with the HMI module and is used to receive the target ,parameters and sensor detection data, perform signal processing, deviation ,calculation and output control signals.

[0037] In this embodiment, the PLC control module is directly connected to the HMI module to receive the target parameters set by the operator. These target parameters include the quantitative target value of the material. , Thickness target value and moisture target These parameters are the basic inputs for subsequent deviation calculation and compensation algorithms.

[0038] In a possible implementation, the PLC control module is connected to the sensor module through a data acquisition unit. The analog signal collected by the sensor module is converted into a digital signal through the data acquisition unit. The analog-to-digital converted signal directly enters the filtering process. In general, the data acquisition unit uses a sliding average filter method to perform preliminary noise reduction on the signal, and the formula is: ; in: The filtered signal is An output value, which is the signal value after filtering and is used for smoothing; Represents the original signal exist The value of the signal at that moment At current location Before and After The data points are weighted averaged. The variable controls the The weighted sum of the sampling points; represents the size of the sliding window, that is, the number of samples processed on average. In this formula, the signal will be based on Continuous data points are smoothed. The larger the value, the more obvious the smoothing effect will be, but it may cause greater delay; Indicates the index of the current sample, indicating the current position of the filtered signal, usually the first points.

[0039] This process can effectively remove high-frequency noise in the signal and maintain the stability and accuracy of the data. In another possible implementation, the filtering process is combined with the fast Fourier transform to analyze the frequency domain characteristics of the signal, thereby further optimizing the signal quality.

[0040] In this embodiment, the deviation calculation unit receives the target parameters from the HMI module and the actual detection data from the data acquisition unit, and calculates the deviation between the two in real time. The deviation calculation formula is: e=r−y, where: e is the deviation value; r is the target parameter value; y is the actual detection value.

[0041] In some embodiments, the deviation calculation unit not only outputs the real-time deviation value, but also analyzes the variation trend of the deviation. For example, when the deviation value continues to increase, the system will trigger an early warning signal and mark possible abnormal areas. This trend analysis provides an important guarantee for the stability of system operation.

[0042] As an option, the deviation calculation unit also supports dynamic threshold adjustment. Under different material types, the allowable range of deviation may be different. For example, in high-humidity materials, the deviation allowable value of the moisture parameter can be automatically adjusted according to preset rules. This dynamic adjustment mechanism improves the flexibility and adaptability of the system.

[0043] The signal output unit is used to generate dynamic control signals and output them to the execution device module. In general, the control signal is generated based on the PID control algorithm, and its formula is as follows: ; in: Indicates the control signal output by the controller; Represents the error value, specifically: ,in is the target value, is the actual measured value; Represents the proportional gain coefficient, gain The larger it is, the stronger the controller responds to the current error; Performance integral gain factor; represents the integral term; represents the differential gain coefficient; Represents the differential term of the error.

[0044] Specifically, the signal output unit generates independent control signals for the deviations of different parameters. For example: For material quantitative deviation , the generated control signal is used to adjust the material conveying speed; For thickness deviation , the generated control signal is used to adjust the pressure of the pressure roller; For moisture deviation The generated control signal is used to control the operating power of the humidifier or dryer.

[0045] In another possible implementation, the signal output unit supports segmented control. For example, for large deviations, the signal output unit will increase the adjustment speed; for small deviations, the adjustment speed will be correspondingly slowed down, thereby achieving a more stable control effect.

[0046] In this embodiment, the PLC control module also supports real-time communication with the signal feedback module. The signal feedback module returns the adjusted parameters of the material to the PLC to form a closed-loop control. Generally, this closed-loop control can effectively suppress the cumulative error in the system and ensure the dynamic consistency of detection and adjustment.

[0047] As an extended function, the PLC control module supports real-time diagnosis of abnormal conditions. For example, when the servo motor is in an abnormal state, the signal output unit will automatically interrupt the output and trigger the system emergency stop function. At the same time, the data acquisition unit will save the sensor data in the abnormal state for subsequent fault analysis.

[0048] In this embodiment, the PLC control module can also support data interaction with external systems. For example, the deviation calculation results and adjustment signals can be transmitted to the central control system of the factory through the communication interface for centralized monitoring and management. This extended function provides a technical basis for industrial-scale multi-device collaboration.

[0049] In some embodiments, the PLC control module also supports predictive control. For example, by analyzing historical data, the PLC can predict future deviation trends, thereby adjusting the control signal before the deviation occurs to avoid the deviation exceeding the allowable range. This predictive control plays an important role in improving the operating efficiency and stability of the system.

[0050] Please see attached Figure 4 , a scanning control module, used to drive the scanning detection device to achieve full coverage scanning of the material surface; In this embodiment, the core components of the scanning control module include a servo motor 4, a position encoder 10, and a scanning path calibration unit. The servo motor 4 is used to provide power for the scanning detection device to achieve a covering scan of the material surface. Specifically, the servo motor 4 is installed at the end of the bottom screw 3 to drive the screw 3 to rotate, thereby driving the detection device to move along the direction of the beam 2. Through the control of the servo motor 4, the detection device can achieve reciprocating motion within the material width range at a preset speed.

[0051] Generally, the speed of the servo motor 4 is set by the system and coordinated with the material conveying speed. As an option, the speed of the servo motor 4 can be dynamically adjusted according to different material widths so that the scanned coverage area can fully match the material width. This method is suitable for production scenarios where the material width is not fixed.

[0052] In a possible implementation, the driving process of the servo motor 4 is combined with real-time feedback control. The position encoder 10 is installed in the detection machine 9 and is used to monitor the specific position of the scanning detection device on the beam 2. The position encoder 10 is based on high-precision angle or displacement data and provides real-time feedback on the motion trajectory of the detection device. Its monitoring parameters include the current position collected in real time. and movement speed Specifically, the position encoder calculates the position deviation using the following formula: ; in: is the current position deviation; is the set target location; The current location collected in real time.

[0053] when deviation When the set threshold is exceeded, the system will automatically adjust the operating parameters of the servo motor to keep the scanning path of the detection device within the predetermined range.

[0054] In this embodiment, the scanning path calibration unit adjusts the scanning trajectory of the detection device in real time according to the feedback information of the position encoder. The calibration unit ensures the accuracy of the scanning path by adjusting the output signal of the servo motor. For example, when the detection device has a slight deviation, the calibration unit adjusts the speed of the motor by the following formula: ; in: is the calibrated speed; is the scaling factor for position correction.

[0055] As an option, the scanning path calibration unit can preset and optimize the path in combination with the actual operating status of the scanning device. For example, for scenes with local complex features on the surface of the material, the scanning accuracy of these areas can be improved by adjusting the coverage density of the scanning path, thereby meeting higher detection requirements.

[0056] Specifically, the servo motor and position encoder of the scanning control module work together to enable the detection device to move along the beam at a stable speed. At the same time, the calibration unit dynamically corrects the scanning trajectory to avoid path deviation caused by external vibration or screw rotation error. Generally, the calibration unit combines the feedback signals of multiple sensors, such as the detection signal of the material width boundary, to ensure the accuracy of the scanning start and end points.

[0057] In another possible implementation, the scanning path calibration unit further optimizes the control logic of the servo motor by simulating the relationship between the material width and the scanning time. Assuming that the material width is , the lateral scanning speed of the detection device is , then the time of a single scan is for: ; This formula is an important reference for dynamically adjusting the scanning speed. For example, when the material width changes, the calibration unit can automatically adjust the operating parameters of the servo motor according to the formula to ensure that the scanning time matches the width.

[0058] In some embodiments, the scanning control module also has a path visualization function. Specifically, the feedback data of the position encoder is transmitted to the HMI module in real time, and the operator can view the scanning progress of the detection device on the HMI interface. For example, the current scanning path will be displayed in the form of a dynamic curve, and the operator can intuitively determine whether the scan covers the material surface.

[0059] In this embodiment, the scanning control module also supports abnormal state detection and processing. For example, when the speed of the servo motor fluctuates abnormally, the position encoder will detect the deviation value beyond the allowable range and trigger the calibration unit to automatically correct it. If the deviation persists, the system will issue an alarm through the HMI module to notify the operator to check and handle it.

[0060] Generally speaking, the scanning control module also has a certain degree of adaptive capability. For example, when the load of the detection device changes, the servo motor will dynamically adjust the output power through feedback control to ensure the stability and accuracy of the scanning motion.

[0061] Please see attached Figure 8 , sensor module, is used to collect the unit area weight, thickness and humidity of the material.

[0062] In this embodiment, the sensor module is composed of a quantitative sensor 11, a thickness sensor 12 and a moisture sensor 13, all of which are integrated into the detection machine 9. Driven by the scanning control module, the detection machine 9 moves in the lateral direction of the material surface, and the sensor module completes the physical parameter collection of each scanning point. Through such a setting, the sensor module can achieve high-frequency and full-coverage material physical parameter detection.

[0063] Specifically, the quantitative sensor 11 is used to collect the weight per unit area of ​​the material. Generally, the quantitative sensor 11 calculates the weight per unit area by detecting the mass change of the material when it passes through. The calculation formula is: ; in: is the weight per unit area of ​​the material; is the mass of the material in the sampling area; is the area of ​​the sampling region.

[0064] As an option, the quantitative sensor can use a detection technology based on pressure or optical interference to further improve the sampling accuracy. For example, in some embodiments, the quantitative sensor uses a high-precision weighing module combined with a fabric width detector to collect the unit weight of the material in dynamic motion, thereby avoiding errors caused by material vibration.

[0065] The thickness sensor 12 is used to measure the thickness of the material. The sensor uses laser ranging technology or ultrasonic reflection technology to achieve high-precision thickness measurement. Generally, the thickness sensor 12 includes a transmitter and a receiver. When the material passes through the detection area, the sensor measures the time difference of the emitted light or sound wave from the transmitter to the material surface and then back to the receiver, and calculates the material thickness based on this. The calculation formula is: ; in: is the thickness of the material; is the distance from the sensor to the reference plane; is the actual distance from the sensor to the material surface.

[0066] In one possible implementation, the detection accuracy of the thickness sensor 12 can be dynamically adjusted. For example, for materials with large thickness variations, the sensor module can increase the sampling frequency to more accurately capture local changes in thickness. This function is particularly useful when detecting materials with uneven thickness.

[0067] The moisture sensor 13 is used to detect the moisture content of the material. Generally, the moisture sensor 13 uses a capacitance method or an infrared absorption method to measure the moisture content of the material. The capacitance method determines the moisture content by detecting the change in capacitance on the surface of the material, and the infrared absorption method calculates the moisture value by the material's absorption rate of infrared light of a specific wavelength. The detection result can be expressed as: ; in: To detect the moisture value of materials in real time; is the mass of the water-containing material; is the mass of the dry material.

[0068] In some embodiments, the working mode of the moisture sensor can be automatically switched according to the type of material. For example, for thin film materials with strong light transmittance, the infrared absorption method can be used preferentially; for opaque fabric materials, the capacitance method can be used preferentially. This multi-mode detection mechanism improves the adaptability of the sensor module.

[0069] As an option, the individual sensors in the sensor module can operate independently or work together in combination. For example, in some cases, the detection results of the thickness sensor can be used as reference data for the quantitative sensor to correct the measurement error caused by material density fluctuations. This collaborative working mechanism improves the overall accuracy of the system's material parameter measurement.

[0070] Generally, the data collected by the sensor module is uploaded to the data acquisition unit of the PLC control module at a high frequency. In order to ensure the accuracy of the collected data, the sensor module also supports real-time self-calibration. For example, when the position of the detection machine is slightly offset, the sensor module can automatically adjust the detection range according to the feedback signal provided by the scanning path calibration unit to ensure the detection accuracy of each sampling point.

[0071] In one possible implementation, the sensor module can also support focused detection of specific areas. For example, when an area of ​​a material is detected to have abnormal parameters, the sensor module will increase the sampling density of the area according to the system instructions and pass the detailed data to the HMI module for real-time display. This focused detection function helps operators quickly locate and deal with material quality problems.

[0072] In some embodiments, the spectral analysis sensor 14 uses spectral analysis technology to analyze the chemical properties of the material, such as the inorganic content or ash content in paper, through the absorption, reflection or scattering signals of light of a specific wavelength on the surface of the material.

[0073] Specific implementation of spectral analysis: Paper detection: Spectral sensors can be used to detect the ash and inorganic content in paper; Thin film testing: used to analyze the molecular characteristics or chemical composition of thin film materials; Non-woven fabric testing: used to determine the stability of material composition during the production process.

[0074] Extended functions of the signal processing method: After the spectral data is collected by the spectral sensor, the signal is processed by the PLC module, including analog-to-digital conversion, filtering processing and spectral feature extraction.

[0075] Spectral feature extraction formula for chemical analysis: ; in: is the concentration of the target component in the material, such as ash percentage; is the spectral intensity at a specific wavelength; is the calibration coefficient, obtained by experimental calibration; The number of wavelengths for the specific spectrum selected.

[0076] The chemical composition data detected by the spectral sensor is compared with the target chemical parameter such as the ash target value through the deviation calculation unit to generate a dynamic compensation signal; Ash compensation algorithm formula: ; ; in: is the target ash value; It is the actual ash value detected in real time; To adjust the values ​​of the operating parameters of the execution equipment; is the chemical parameter compensation coefficient; is the deviation value of ash content; The benchmark operating parameters.

[0077] Please see attached Figure 5 , execution equipment module, used to adjust the moisture, concentration, pressure and conveying speed of the material.

[0078] In this embodiment, the humidifier in the execution equipment module is used to increase and adjust the moisture content of the material. Generally, the humidifier works by micronized spray or ultrasonic steam humidification to evenly spray moisture onto the surface of the material to supplement the lack of moisture in the material due to drying or process loss. The humidification intensity of the humidifier is controlled by the control signal output by the PLC module. The calculation formula of moisture adjustment is: ; in: The amount of water regulation; is the gain coefficient of the humidifier; is the moisture target value; It is the real-time detection of material moisture value.

[0079] Specifically, the spray intensity and distribution range of the humidifier can be automatically adjusted according to the width of the material. For example, for wide materials, the humidifier can achieve uniform humidification by adjusting the number of spray heads and the spray angle, thereby avoiding the phenomenon of insufficient moisture in the edge area.

[0080] The dryer is used in the execution equipment module to reduce the moisture content of the material. The dryer generally uses hot air or infrared heating to increase the temperature of the material surface to accelerate the evaporation of moisture. It is dynamically calculated and adjusted by the PLC module, and the calculation formula is: ; in: is the operating power of the dryer; is the control coefficient of the dryer; is the moisture target value; It is the real-time detection of material moisture value.

[0081] As an option, the dryer can be adjusted according to the material moving speed Dynamically adjust its power output. For example, when the material moves faster, the system will automatically increase the dryer's output power to ensure that the moisture can evaporate quickly in a short time. This dynamic adjustment mechanism is particularly important for maintaining the stability of high-speed production lines.

[0082] Specifically, the dryer can also precisely control the drying effect by adjusting the hot air temperature, air volume and infrared lamp power distribution. For example, for materials with different humidity gradients, the dryer will prioritize the high humidity area as the key drying object, thereby achieving overall moisture uniformity.

[0083] The pressure regulating valve is a core component in the actuator module used to adjust the fluid pressure during material delivery. The pressure regulating valve maintains the stability of material thickness and flow rate by controlling the fluid pressure in the delivery path. Its adjustment is based on the control signal from the PLC module, which is determined by the deviation between the actual material thickness and the target thickness. The adjustment formula is: ; in: is the regulated flow rate; is the flow coefficient of the pressure valve; is the target pressure difference.

[0084] In one possible implementation, the pressure regulating valve can be dynamically adjusted in combination with the thickness value collected in real time by the sensor module. For example, when the material thickness exceeds the allowable range, the pressure regulating valve will quickly adjust the fluid flow to ensure that the material thickness is within the target range.

[0085] As an option, the pressure regulating valve can also work in conjunction with the humidifier and dryer. For example, when the thickness deviation of the material is mainly caused by humidity fluctuations, the system can prioritize adjusting the humidity through the humidifier or dryer, and the pressure regulating valve can fine-tune the small deviations during the conveying process.

[0086] Generally, the components in the execution equipment module can operate independently, but in some complex process scenarios, these components can also work together. For example: When the moisture deviation of the material is large, the humidifier and dryer will increase and decrease the moisture respectively by time-sharing operation, while the pressure regulating valve will adjust the delivery pressure at the same time to accelerate the redistribution of moisture; When material thickness deviation causes uneven moisture distribution, the dryer will give priority to drying the thicker areas, while the humidifier will supplement the thin areas to ensure the consistency of moisture on the material surface.

[0087] In another possible implementation, the execution equipment module supports multi-zone independent adjustment. For example, for wide-width materials, the humidifier, dryer, and pressure regulating valve can be divided into several independent control units according to the horizontal area, and each unit independently adjusts the operating parameters according to the detection data in the area. This partition adjustment method effectively improves the control accuracy of wide-width materials.

[0088] Please see attached Figure 7 ,Compensation algorithm module is used to dynamically correct the control signal according to the deviation of the material's physical parameters.

[0089] In this embodiment, the compensation algorithm module includes a quantitative compensation unit, a thickness compensation unit and a moisture compensation unit, and each compensation unit corresponds to the deviation calculation and control signal generation of different physical parameters.

[0090] Specifically, the quantitative compensation unit is used to adjust the material conveying speed according to the deviation of the material unit area weight. The deviation calculation formula is: ; in: is the deviation value of weight per unit area; is the quantitative target value; It is the actual quantitative value of the material.

[0091] In general, the material conveying speed is inversely proportional to the weight per unit area. The quantitative compensation unit is based on the deviation value. Dynamically adjust conveying speed , the adjustment formula is: ; in: is the adjustment amount of the conveying speed; It is a quantitative compensation coefficient used to adjust the adjustment rate.

[0092] As a possible implementation, when the deviation When the preset threshold is exceeded, the quantitative compensation unit will prioritize adjusting the material delivery speed and send an early warning signal to the operator to indicate the abnormality.

[0093] The thickness compensation unit is used to adjust the pressure of the pressing roller according to the deviation of the material thickness. The deviation is calculated using the following formula: ; in: is the thickness deviation value; is the target thickness value; is the real-time thickness of the material.

[0094] The thickness compensation unit is based on the deviation value Adjusting the roller pressure , the adjustment formula is: ; in: is the roller pressure adjustment amount; is the thickness compensation coefficient.

[0095] In some embodiments, the thickness compensation unit can be adjusted in sections according to the local thickness variation of the material. For example, if the thickness distribution of the material is uneven in the width direction, the system will specifically adjust the roller pressure in a certain area to improve the overall thickness uniformity.

[0096] Moisture compensation units are used to adjust the operating parameters of humidifiers or dryers according to deviations in material humidity. The calculation formula for the deviation is: ; in: is the humidity deviation value; is the moisture target value; It is the real-time detection of material moisture value.

[0097] The moisture compensation unit controls the material humidity by adjusting the spray intensity of the humidifier or the operating power of the dryer. The adjustment formula is as follows: ; in: The adjustment amount of the humidifier or dryer operating parameters; is the moisture compensation coefficient.

[0098] As an option, the moisture compensation unit can prioritize abnormal areas in case of large humidity changes. For example, when the humidity deviation in a certain area is significantly higher than that in other areas, the system will increase the drying intensity in this area, while other areas will maintain the original operating parameters.

[0099] In general, each compensation unit in the compensation algorithm module operates independently. However, under some complex process requirements, these compensation units can also work together. For example: When the thickness deviation and humidity deviation of the material exist at the same time, the thickness compensation unit and the moisture compensation unit can coordinately adjust the pressure of the pressure roller and the operating parameters of the humidifier; When the weight per unit area and the humidity deviation of the material exceed the standard at the same time, the quantitative compensation unit adjusts the conveying speed first, while the moisture compensation unit dynamically adjusts the operating power of the humidifier or dryer.

[0100] As a possible extension, the compensation algorithm module can also support independent compensation functions in multiple regions. For example, for wide-width materials, the system can divide the material into several regions, and the parameter deviation of each region is calculated and adjusted by an independent compensation unit. Independent control between regions can improve compensation accuracy, especially when the physical parameters of the material are unevenly distributed.

[0101] In general, the compensation algorithm module will optimize the compensation process in combination with historical deviation data. For example, the system can dynamically adjust the quantitative compensation coefficient by analyzing the trend of the deviation value. , thickness compensation coefficient and moisture compensation coefficient , to meet the needs of different materials and process conditions.

[0102] The signal feedback module is connected with the sensor module and the PLC control module, and is used for collecting the adjusted material parameters in real time and updating the control signal.

[0103] Please see attached Figure 2 -Attached Figure 3 , the scanning detection device comprises: There are two cabinets 1, and two beams 2 are connected between the two cabinets 1. Screw rods 3 are arranged inside the two beams 2. One end of the two screw rods 3 is connected to a pulley 5. The two pulleys 5 are connected by a belt 6. The outer wall of the top screw rod 3 is threadedly connected to a movable seat 2 8, and the outer wall of the bottom screw rod 3 is threadedly connected to a movable seat 1 7. Detection machines 9 are installed on the opposite sides of the movable seat 1 7 and the movable seat 2 8.

[0104] The high-speed web material scanning detection control signal processing method described below and the high-speed web material scanning detection control system described above can correspond to each other.

[0105] Please see attached Fig. 9 -Attached Fig.12 A method for processing control signals for high-speed surface material scanning detection comprises the following steps: S1. The operator inputs the target parameters, including the target quantitative value, moisture value and thickness value of the material through the HMI module; S2, start the scanning control module, and drive the scanning detection device through the servo motor 4 to achieve full coverage scanning of the material surface; S3, collecting the unit area weight, thickness and humidity data of the material through the sensor module; S4, performing analog-to-digital conversion and filtering processing on the collected analog signal through the PLC control module; S5. Calculate the deviation between the target parameter and the actual detection value and identify the adjustment requirement; S6. Dynamically generate an optimized control signal through a compensation algorithm module according to the deviation value; S7, output control signals to the execution equipment module to adjust the moisture, concentration, thickness and conveying speed of the material; S8, enable the signal feedback module, collect the adjusted material parameters in real time, and input the feedback information into the PLC control module for updating; S9. Form a closed-loop control logic to make the material parameters continuously approach the target value.

[0106] Regarding the control signal processing method of the high-speed material scanning and detection control system, the solution realizes precise closed-loop control of material parameters such as quantity, moisture, and thickness through multi-module collaboration. Specifically, the HMI module is used to input the target value and display the parameter changes in real time. The scanning control module performs full coverage scanning through the servo motor drive detection device. The sensor module collects data in real time and feeds back to the PLC control module, which completes the deviation calculation and signal processing, and optimizes the control signal output to the execution device module in combination with the compensation algorithm module. Through the signal feedback module, the system realizes closed-loop adjustment, so that the material parameters dynamically approach the target value and improves the control accuracy.

[0107] On this basis, the system adopts mechanisms such as upper and lower limit protection and manual / automatic operation switching to meet the needs of different scenarios.

[0108] In this embodiment, the control signal processing method includes the following steps: The operator inputs the target parameters, including the target weight value, moisture value and thickness value of the material, through the HMI module, and monitors the system status in real time. The target parameters are transmitted to each functional module through the PLC control module as the core reference value.

[0109] The HMI module also displays historical curves and real-time quantitative, moisture and thickness data of materials, which facilitates the operator to manually adjust the process parameters. During system operation, the operator can switch between "manual / automatic" operation modes. In manual mode, all adjustment parameters are given directly by the operator; in automatic mode, the system dynamically adjusts according to real-time deviations.

[0110] Through the scanning control module, the servo motor 4 is started to drive the scanning detection device to perform a full coverage scan of the material surface. The control logic of the scanning path includes: Upper and lower limit constraints: The scanning range of the detection device is set to [lower limit, upper limit] to ensure complete coverage and avoid repeated scanning.

[0111] Trajectory adjustment: Combined with the real-time feedback of the position encoder 10, the scanning path calibration unit optimizes the running trajectory of the detection device.

[0112] The scanning device is driven by the screw rod 3, and the detection machines 9 are respectively installed on the top and the bottom to realize the parameter collection of different positions of the material.

[0113] During the scanning process, the weight per unit area, thickness and humidity of the material are collected by the sensor module. In this embodiment, the specific collection equipment includes: Quantitative sensor 11: installed in the detection machine 9, used to detect the unit area weight of the material.

[0114] Thickness sensor 12: installed in the detection machine 9, used to measure the thickness of the material.

[0115] Moisture sensor 13: installed in the detection machine 9, used to collect the moisture of the material.

[0116] The analog signal output by the sensor module is converted into digital form and filtered by the PLC control module.

[0117] In this embodiment, the PLC control module calculates the deviation between the target value and the actual detection value: e=r−y, where: e is the deviation value; r is the target parameter value; y is the actual detection value.

[0118] Through the compensation algorithm module, the optimized control signal is dynamically generated according to the deviation value: Quantitative compensation: ; ; in, is the adjustment amount of the conveying speed; is the quantitative compensation coefficient; is the weight deviation per unit area ( = ), is the adjusted conveying speed; The base conveying speed.

[0119] This formula ensures that the weight per unit area remains within the target range by dynamically adjusting the conveyor speed.

[0120] Thickness compensation: ; ; in: is the roller pressure adjustment amount, is the thickness compensation coefficient, is the thickness deviation ( = ), is the adjusted roller pressure; is the reference roller pressure.

[0121] Through dynamic adjustment of the roller pressure, precise control of material thickness can be achieved.

[0122] Moisture compensation: ; ; in: The adjustment amount of the humidifier or dryer operating parameters; is the moisture compensation coefficient; is the moisture deviation ( = ); for Operating parameters after compensation; The benchmark operating parameters.

[0123] Moisture compensation ensures that the material moisture is close to the target value by dynamically adjusting the spray intensity of the humidifier or the power of the dryer.

[0124] Dynamically optimized control signals are transmitted to the execution equipment module: Humidifiers increase the moisture content of materials; dryers reduce the moisture content of materials; pressure regulating valves adjust the conveying pressure; and conveying systems adjust the speed to control the weight per unit area.

[0125] In order to ensure the safety and stability of system operation, the control signal needs to be set with upper and lower limit protection. The formula is as follows: ; in: is the operating parameter after compensation; , The upper and lower limits of the operating parameters.

[0126] The upper and lower limit protection mechanism ensures that the execution equipment operates within a reasonable range.

[0127] In this embodiment, the signal feedback module collects the adjusted material parameters such as quantity, moisture and thickness in real time. The feedback data is processed by the PLC control module, the deviation calculation is updated, and then transmitted to the compensation algorithm module.

[0128] In the above process, the system continuously optimizes the equipment operation status through feedback closed-loop logic, so that the material parameters continue to approach the target value. The closed-loop logic has a short response time and high adjustment accuracy, which is suitable for high-speed flat material production.

[0129] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high-speed material scanning detection control system, characterized in that: include: HMI module, which is used by the operator to input target parameters and display the quantitative data, moisture data, thickness data, historical curves and process parameter adjustments of the material in real time; A PLC control module, connected to the HMI module, for receiving the target parameters and sensor detection data, performing signal processing, deviation calculation and outputting control signals; A scanning control module is used to drive the scanning detection device to achieve full coverage scanning of the material surface; Sensor module, used to collect the unit area weight, thickness and humidity of the material; Execution equipment module, used to adjust the moisture, concentration, pressure and conveying speed of the material; Compensation algorithm module, used to dynamically correct the control signal according to the deviation of the material's physical parameters; The signal feedback module is connected to the sensor module and the PLC control module, and is used for collecting the adjusted material parameters in real time and updating the control signal.

2. A high-speed web material scanning detection control system according to claim 1, characterized in that: The scanning detection device comprises: Two cabinets (1), two crossbeams (2) are connected between the two cabinets (1), screw rods (3) are arranged inside the two crossbeams (2), one end of the two screw rods (3) is connected to a pulley (5), the two pulleys (5) are connected by a belt (6), the outer wall of the top screw rod (3) is threadedly connected to a movable seat 2 (8), the outer wall of the bottom screw rod (3) is threadedly connected to a movable seat 1 (7), and detection machines (9) are installed on the opposite sides of the movable seat 1 (7) and the movable seat 2 (8).

3. A high-speed web material scanning detection control system according to claim 2, characterized in that: The scanning control module comprises: A servo motor (4) is mounted on the end of the screw rod (3) at the bottom and is used to drive the scanning detection device to achieve full coverage scanning of the material surface; A position encoder (10) installed in the detection machine (9) and used for real-time monitoring and correction of the operating position of the scanning detection device; The scanning path calibration unit is used to adjust the scanning trajectory of the scanning detection device in real time according to the position information fed back by the position encoder.

4. A high-speed web material scanning detection control system according to claim 1, characterized in that: The execution device module comprises: Humidifier, used to increase and regulate the moisture content of materials; Dryer, used to reduce the moisture content of materials; Pressure regulating valve is used to adjust the fluid pressure during material transportation.

5. The high-speed web material scanning detection control system according to claim 1, characterized in that: The PLC control module comprises: A data acquisition unit, used for performing analog-to-digital conversion and filtering processing on the analog signals collected by the sensor; A deviation calculation unit, used for calculating the deviation between the set target value and the actual detection value; The signal output unit is used to generate a dynamic control signal according to the deviation.

6. A high-speed web material scanning detection control system according to claim 1, characterized in that: The compensation algorithm module includes: A quantitative compensation unit is used to adjust the material conveying speed according to the deviation of the material weight per unit area; Thickness compensation unit, used to adjust the roller pressure according to the deviation of material thickness; Moisture compensation unit, used to adjust the operating parameters of the humidifier or dryer according to the deviation of material humidity.

7. A high-speed web material scanning detection control system according to claim 2, characterized in that: The sensor module comprises: A quantitative sensor (11), which is installed in the detection machine (9) and is used to collect the weight per unit area of ​​the material; A thickness sensor (12) installed in the detection machine (9) for measuring the thickness of the material; A moisture sensor (13), which is installed in the detection machine (9) and is used to detect the moisture content of the material; The spectral analysis sensor (14) is installed in the detection machine (9) and is used to detect the chemical composition or inorganic content on the surface of the material, and realizes real-time analysis of chemical parameters in combination with the signal processing function of the PLC control module.

8. A method for processing control signals for high-speed surface material scanning detection, characterized in that: The following steps are involved: S1. The operator inputs the target parameters, including the target quantitative value, moisture value and thickness value of the material through the HMI module; S2, starting the scanning control module, and driving the scanning detection device through the servo motor (4) to achieve full coverage scanning of the material surface; S3, collecting the unit area weight, thickness and humidity data of the material through the sensor module; S4, performing analog-to-digital conversion and filtering processing on the collected analog signal through the PLC control module; S5. Calculate the deviation between the target parameter and the actual detection value and identify the adjustment requirement; S6. Dynamically generate an optimized control signal through a compensation algorithm module according to the deviation value; S7, output control signals to the execution equipment module to adjust the moisture, concentration, thickness and conveying speed of the material; S8, enable the signal feedback module, collect the adjusted material parameters in real time, and input the feedback information into the PLC control module for updating; S9. Form a closed-loop control logic to make the material parameters continuously approach the target value.

Images