Film coating control method and device for injection-molded finished products

Abstract

The application provides a film covering control method and device for injection molding finished products, and relates to the technical field of film covering control. The method comprises the following steps: reading the first characteristics of the finished products and the film characteristics, determining the control constraints, reading the bottom layer control mechanism, training the limiting decision maker and the solidification decision maker, identifying the film quality standard and the number of film layers, interacting and fusing the single decision scheme, determining the film covering strategy, performing the film covering control, establishing the regulation plan library, synchronously performing the film covering monitoring, and combining the digital feedback device to perform the film covering regulation and management. The application can solve the technical problem that the prior art lacks comprehensive consideration of the injection molding finished products and the film characteristics, which leads to the lack of pertinence and accuracy of the film covering strategy, further affects the product film covering quality and production efficiency, realizes the fine control of the film covering process, and improves the product quality and production efficiency.

Description

Technical Field

[0001] This application relates to the field of coating control technology, and in particular to a coating control method and apparatus for injection-molded finished products. Background Technology

[0002] With the development of industrial technology, injection molding technology has also been continuously advancing, from early basic molding to advanced technologies such as multi-component injection molding and in-mold assembly injection molding. These technological advancements have broadened the application areas of injection-molded products and improved their quality. In some applications, injection-molded products require further protection or aesthetic enhancement, leading to the development of coating processes. Coating is a process of covering the surface of a product with a thin film, which can improve its wear resistance, corrosion resistance, and water resistance, while also increasing its aesthetic appeal. In the development of coating processes, different coating materials and technologies have emerged. For example, an adhesive is applied to a plastic film using a roller coating device, then the film is softened by heating with a hot press roller, and finally pressed against the injection-molded product to form a protective coating. This coating control method ensures the uniformity and firmness of the coating, improving the durability of the product.

[0003] Currently, traditional lamination techniques often fail to fully consider the geometric, material, and surface characteristics of the injection-molded product, as well as the unique properties of the film, when formulating lamination strategies. This lack of personalization can lead to poor lamination results, such as bubbles, wrinkles, or loose adhesion, thus affecting the overall quality and appearance of the product. Furthermore, inappropriate lamination strategies can increase production time and costs, and reduce production efficiency.

[0004] In summary, existing technologies do not adequately consider the comprehensive characteristics of injection-molded finished products and films, resulting in a lack of targeted and precise coating strategies, which further affects the coating quality and production efficiency of products. Summary of the Invention

[0005] The purpose of this application is to provide a method and apparatus for controlling the coating of injection-molded finished products, in order to solve the technical problem that the existing technology does not take into account the comprehensive characteristics of injection-molded finished products and films, resulting in a lack of targeted and precise coating strategies, which further affects the coating quality and production efficiency of products.

[0006] In view of the above problems, this application provides a method and apparatus for controlling the coating of injection molded finished products.

[0007] In a first aspect, this application provides a coating control method for injection-molded finished products. The method is implemented using a coating control device for injection-molded finished products. The method includes: reading a first characteristic of the injection-molded finished product and the film characteristics of a pre-coated film, wherein the first characteristic includes geometric characteristics, material characteristics, and surface characteristics; determining control constraints based on the first characteristic and the film characteristics; reading the underlying control mechanism of the injection molding machine, and combining the control constraints to train a limit decision-maker and a curing decision-maker, and performing integrated collaborative generation of a coating decision model; and identifying the coating quality. The system determines the standard and number of coating layers, and feeds back factors related to the coating scenario. It then combines these factors with the coating decision model for independent analysis and verification by the decision-maker, interactively integrating individual decision schemes to determine the coating strategy. This strategy has hierarchical stage identifiers, and the number of coating layers can be one or more. The coating strategy is transmitted to the coating control system to execute full-cycle coating control of the coating machine. A dynamic coating control plan library is constructed, and communication connections are established between the control plan library, the digital feedback device, and the coating control system. Simultaneous coating monitoring is performed, and coating control management is conducted in conjunction with the digital feedback device.

[0008] Secondly, this application also provides a coating control device for injection-molded finished products, used to execute a coating control method for injection-molded finished products as described in the first aspect, wherein the device includes: a finished product characteristic reading module, used to read a first characteristic of the injection-molded finished product and the film characteristics of the pre-coated film, the first characteristic including geometric characteristics, material characteristics, and surface characteristics; a constraint condition determination module, used to determine control constraints based on the first characteristic and the film characteristics; a decision model acquisition module, used to read the underlying control mechanism of the injection molding machine, and in conjunction with the control constraints, train a limit decision-maker and a curing decision-maker to perform integrated collaborative generation of a coating decision model; and a coating strategy acquisition module. The coating strategy acquisition module is used to identify coating quality standards and the number of coating layers, and to transmit coating scenario factors back. It combines these with the coating decision model to perform independent analysis and verification by the decision-maker, interactively integrating individual decision schemes to determine the coating strategy. The coating strategy has hierarchical stage identifiers, and the number of coating layers is one or more. The coating control module transmits the coating strategy to the coating control system to execute full-cycle coating control of the coating machine. The pre-plan library construction module constructs a control pre-plan library for dynamic coating and establishes communication connections between the control pre-plan library, the digital feedback device, and the coating control system. The control management module synchronously monitors the coating and manages the coating control in conjunction with the digital feedback device.

[0009] One or more technical solutions provided in this application have at least the following technical effects or advantages: By reading the first characteristic of the injection-molded finished product and the film characteristics of the pre-coated film, the first characteristic includes geometric characteristics, material characteristics, and surface characteristics; based on the first characteristic and the film characteristics, control constraints are determined; the underlying control mechanism of the injection molding machine is read, and combined with the control constraints, a limit decision-maker and a curing decision-maker are trained to integrate and collaboratively generate a coating decision model; coating quality standards and coating quantity are identified, and coating scenario factors are fed back. Combined with the coating decision model, the decision-makers are independently analyzed and verified, and individual decision schemes are interactively integrated to determine the coating strategy, wherein the coating strategy has hierarchical stages. The method identifies that the number of coating layers is one or more; transmits the coating strategy to the coating control system to execute the full-cycle coating control of the coating machine; constructs a control plan library for dynamic coating and establishes a communication connection between the control plan library, the digital feedback device, and the coating control system; synchronously monitors the coating process and manages the coating control in conjunction with the digital feedback device. This effectively solves the technical problem that the existing technology does not adequately consider the comprehensive characteristics of injection-molded finished products and films, resulting in a lack of targeted and precise coating strategies, which further affects the coating quality and production efficiency. This achieves refined control of the coating process and improves product quality and production efficiency.

[0010] The above description is merely an overview of the technical solution of this application. To better understand the technical means of this application and to facilitate its implementation according to the description, and to make the above and other objects, features, and advantages of this application more apparent, specific embodiments of this application are described below. It should be understood that the content described in this section is not intended to identify key or important features of the embodiments of this application, nor is it intended to limit the scope of this application. Other features of this application will become readily apparent through the following description. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely exemplary. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0012] Figure 1 This is a schematic flowchart of a coating control method for injection-molded finished products according to this application; Figure 2 This is a schematic diagram of the structure of a coating control device for injection-molded finished products according to this application.

[0013] Explanation of reference numerals in the attached figures: The module includes: finished product characteristic reading module 11, constraint condition determination module 12, decision model acquisition module 13, coating strategy acquisition module 14, coating control module 15, contingency plan library construction module 16, and regulation and management module 17. Detailed Implementation

[0014] This application provides a coating control method and apparatus for injection-molded finished products, which solves the technical problem that the existing technology does not take into account the comprehensive characteristics of injection-molded finished products and films, resulting in a lack of targeted and precise coating strategies, which further affects the coating quality and production efficiency. It achieves refined control of the coating process and improves product quality and production efficiency.

[0015] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. It should be understood that this application is not limited to the exemplary embodiments described herein. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application. It should also be noted that, for ease of description, only the parts related to this application are shown in the accompanying drawings, not all of them.

[0016] Example 1 Please see the appendix Figure 1 This application provides a method for controlling the coating of injection-molded finished products, wherein the method is applied to a coating control device for injection-molded finished products, and the method specifically includes the following steps: S1: Read the first characteristics of the injection-molded finished product and the film characteristics of the pre-coated film, the first characteristics including geometric characteristics, material characteristics and surface characteristics; Specifically, the primary characteristics of injection-molded products include geometric characteristics, material characteristics, and surface characteristics. Geometric characteristics include dimensional accuracy, ensuring high dimensional precision and stability in the injection-molded product, achieved through the precise molding of plastic under high temperature and pressure. Precise dimensions help ensure good adhesion during lamination and the aesthetics of the final product. Shape complexity refers to the ability of injection molding to manufacture products with complex shapes. Different shapes can affect the difficulty and effect of lamination, therefore, a thorough evaluation of the product's geometry is necessary before lamination. Material characteristics include plastic type, allowing the use of various plastic materials such as ABS, PC, PE, and PP. Different materials have different physical and chemical properties, which influence the selection of lamination materials and the parameter settings of the lamination process. Material properties, such as the hardness, toughness, heat resistance, and chemical stability of the plastic material, significantly impact the lamination effect. For example, softer plastics may adhere more easily to lamination materials, while harder plastics may require higher temperatures and pressures to achieve a good lamination result. Surface characteristics also include surface finish, as the surface finish of the injection-molded product directly affects the quality and appearance of the lamination. Smooth surfaces facilitate uniform coating, while rough surfaces can lead to bubbles or unevenness in the coating. Surface treatments, such as spraying and electroplating, may be necessary for some injection-molded products to enhance aesthetics or improve performance. These surface treatments can affect the adhesion and durability of the coating. The characteristics of the pre-coated film include its material composition; pre-coated films are typically made of polymers such as polyester, offering good transparency and mechanical strength. Thickness and uniformity significantly impact the coating effect. Films that are too thin may break easily, while films that are too thick may affect the product's appearance and performance.

[0017] S2: Based on the first characteristic and the thin film characteristic, determine the control constraint conditions; Specifically, the control constraints are as follows: Select appropriate film size and shape based on the dimensions and shape of the injection-molded finished product to ensure the film completely covers the surface of the finished product with sufficient allowance for easy handling and lamination. The film material should be compatible with the plastic material of the injection-molded finished product to avoid chemical reactions or damage to the surface. The film should have good adhesion, adhering tightly to the surface of the injection-molded finished product without gaps or air bubbles. Adjust parameters such as pressure, temperature, and speed of the laminating machine according to the film thickness and uniformity to ensure the film adheres evenly and smoothly to the surface of the finished product. The selected film should have good weather resistance and chemical stability to adapt to the possible operating environments of the injection-molded finished product. The film should be easy to handle and process, facilitating lamination operations on the production line.

[0018] S3: Read the underlying control mechanism of the injection molding machine, combine it with the control constraints, train the limit decision-maker and the solidification decision-maker, and integrate and collaboratively generate the coating decision model; Specifically, the underlying control of an injection molding machine includes motion control, temperature control, and pressure control. This is obtained through technical documentation provided by the injection molding machine manufacturer, API interfaces, or direct communication with the machine's control system. Key control parameters related to the coating process, such as injection speed, injection pressure, mold temperature, and mold opening / closing speed, are extracted from the machine's underlying control mechanism. These parameters directly affect the quality and efficiency of the coating. Control constraints, such as geometric matching, material compatibility, and surface adhesion, are combined with the injection molding machine's control parameters. Each constraint is quantified to correlate it with the machine's control parameters. Based on the control constraints and the injection molding machine's control parameters, a limit decision-maker is trained. This decision-maker determines whether the current control parameters meet all constraints and provides adjustment suggestions or limit instructions accordingly. For example, if an excessively high injection speed may lead to uneven film adhesion, the limit decision-maker will suggest reducing the injection speed. The curing decision-maker is primarily responsible for determining whether the curing process after coating has achieved optimal results based on the real-time status and control parameters of the injection molding machine. This requires considering multiple factors such as curing time, temperature, and pressure. Through training, the curing decision-maker can learn the optimal curing conditions and provide adjustment suggestions accordingly. Integrating the limit decision-maker and the curing decision-maker forms a collaborative coating decision-making model. This model can provide the optimal coating control strategy based on the real-time status and control parameters of the injection molding machine, while considering multiple constraints.

[0019] S4: Identify the coating quality standards and the number of coating layers, and return the coating scenario factors. Combine the coating decision model to perform independent analysis and verification of the decision-maker, interactively integrate single decision schemes, and determine the coating strategy. The coating strategy has hierarchical stage identifiers, and the number of coating layers is one or more layers. Specifically, coating quality standards include gloss, adhesion, abrasion resistance, and weather resistance. The number of coating layers may be one or more. Multi-layer coating requires consideration of the compatibility and interaction between layers. Relevant factors of the coating scenario, such as ambient temperature, humidity, operator skill level, and equipment condition, are fed back into the decision model. Based on control constraints and injection molding machine control parameters, the model analyzes whether coating can be performed under current conditions and how to perform it. For example, if the ambient temperature is too low, it may lead to poor film adhesion, and the limit decision-maker will provide warnings or adjustment suggestions. The curing decision-maker analyzes whether the curing process has achieved optimal results based on curing conditions, such as time, temperature, pressure, and the characteristics of the coating material. The curing decision-maker provides suggestions for adjusting curing conditions to ensure coating quality. The outputs of the limit and curing decision-makers are interactively integrated. This includes weighing the suggestions and constraints between different decision-makers to form a comprehensive and feasible coating solution. The final coating strategy is determined. This strategy includes specific operating steps, control parameter settings, and expected results. Meanwhile, considering the hierarchical and phased nature of the lamination process, the strategy should include hierarchical and phased indicators to guide operators in taking appropriate measures at different lamination stages. Hierarchical: If multi-layer lamination is used, the material, thickness, curing conditions, etc., of each layer need to be clearly defined, and compatibility and stability between layers must be ensured. Phased: The entire lamination process should be divided into different stages, such as preparation, bonding, and curing, with clear objectives and operating guidelines set for each stage.

[0020] S5: Transmit the coating strategy to the coating control system to execute the full-cycle coating control of the coating machine; Specifically, the lamination strategy is transmitted to the central processing unit or programmable logic controller (PLC) of the lamination control system via an appropriate interface, such as a network interface, USB interface, or other data communication methods. Upon receiving the strategy, the lamination control system parses it and stores it in the system's memory. Based on the hierarchical stage identifiers in the lamination strategy, the lamination control system performs initialization settings, configuring corresponding parameters such as temperature, pressure, speed, and time. It checks and ensures that all sensors and actuators, such as heaters, pressure valves, and motors, are in normal working condition. According to the strategy, the control system automatically adjusts the laminator's parameters to preset values ​​and prepares the necessary film materials and other auxiliary materials. Under the precise control of the control system, the laminator begins to bond the film onto the injection-molded finished product. During this stage, the control system monitors the bonding process in real time to ensure a tight bond between the film and the finished product surface, preventing the formation of bubbles or wrinkles. After bonding is complete, the curing stage begins. The control system precisely controls the heating elements and pressure devices according to the curing conditions set in the strategy, such as temperature, time, and pressure, to ensure a strong adhesion between the film and the finished product. After curing, the control system automatically enters the cooling phase to reduce the temperature of the product and film, preventing poor adhesion due to thermal expansion and contraction. Once cooling is complete, excess film is automatically peeled off. At the end of each phase, the control system performs quality checks, such as inspecting the film for smoothness and the presence of air bubbles. This information is fed back to the control system for necessary adjustments and optimizations.

[0021] S6: Construct a control plan library for dynamic film coating, and establish a communication connection between the control plan library, the digital feedback device, and the film coating control system; Specifically, the contingency plans are categorized into different types, such as temperature control plans, pressure control plans, and material compatibility plans. For each category, specific control plans are developed. For example, the temperature control plan includes measures to be taken when the temperature is too low or too high. Suitable communication protocols, such as TCP / IP, Modbus, and OPC UA, are selected to ensure smooth communication between the control plan library, digital feedback devices, and the coating control system. Digital feedback devices are used to monitor key parameters in the coating process in real time and feed this data back to the control plan library and the coating control system. Digital feedback devices are configured to monitor key parameters such as temperature, pressure, and speed according to the needs of the coating process. It is ensured that the data from the digital feedback devices remains synchronized with the data from the coating control system and that they are calibrated regularly to improve data accuracy.

[0022] S7: Simultaneously monitor the film coating and manage the film coating control in conjunction with the digital feedback device.

[0023] Specifically, digital feedback devices are used to monitor key parameters in the lamination process in real time, such as temperature, pressure, speed, and film adhesion. After receiving the real-time data, the lamination control system compares it with preset standard values ​​or historical data. This comparison identifies any deviations from the standard, such as abnormal temperature, insufficient pressure, or poor film adhesion. Once an anomaly is detected, the lamination control retrieves the corresponding pre-set plan from its control plan library. Based on the plan, automatic adjustments are made, such as adjusting parameters like temperature, pressure, or speed, to correct deviations in the lamination process.

[0024] Furthermore, step S2 of this application also includes: Identify the geometric characteristics of the injection-molded finished product and determine key spatial positioning points; Identify the film size based on the film characteristics, and determine the first constraint condition based on the spatial positioning point and the film utilization rate, wherein the film utilization rate must be higher than a critical threshold standard; Based on material properties, surface properties, and adhesive properties, a second constraint condition is determined, wherein the material properties include the injection-molded finished product and the pre-coated film, and the second constraint condition is a critical parameter control constraint for measuring material deformation; The control constraints are determined based on the first constraint and the second constraint.

[0025] Specifically, a detailed analysis of the shape, size, and surface structure of the injection-molded finished product is conducted. Key spatial positioning points are identified, including protrusions, grooves, edges, and other characteristic locations. Based on the film's material, thickness, elasticity, and other properties, appropriate film dimensions are determined. The film's utilization rate during the lamination process is calculated using these spatial positioning points. A critical threshold for film utilization is set to ensure that the utilization rate exceeds this standard during actual lamination, thus forming the first constraint. This helps reduce material waste and improve economic efficiency. The material properties of the injection-molded finished product and the pre-coated film are analyzed, such as hardness, toughness, and thermal stability. Surface characteristics of the finished product and film, such as roughness and hydrophilicity / hydrophobicity, affect the selection of adhesives and bonding performance. The stability and reliability of the bonding process are evaluated by comprehensively considering adhesive properties such as viscosity, curing speed, and adhesive strength. Based on the above material, surface, and adhesive properties, a critical parameter constraint for measuring material deformation is determined, i.e., the second constraint. This condition ensures that the material will not undergo unacceptable deformation or damage during the lamination process. By combining the first and second constraints, a comprehensive set of control constraints is formed. These constraints will guide each stage of the coating process, including film selection, cutting, positioning, and bonding.

[0026] Furthermore, this application also includes: Identify the first constraint condition, combine it with the limit decision-maker, perform film limit optimization based on film utilization rate, and determine the film utilization scheme, wherein the optimization criteria are positive iteration and negative regression; Based on the aforementioned film utilization scheme, the injection-molded finished product, the film coating mechanism, and the pre-coated film are coaxially controlled and limited according to the spatial positioning point to determine the limiting strategy. The limiting strategy is a dynamic strategy for the entire film coating cycle of the finished product.

[0027] Specifically, the goal is to improve film utilization, ensuring it exceeds a set critical threshold. An optimization criterion of iterative optimization followed by regression is employed. If a solution improves film utilization, iteration continues along that direction; if a solution reduces utilization, regression occurs. A limit decision-maker provides decision support and guides the optimization process based on the current film utilization and the first constraint. Through this optimization process, a film utilization scheme that satisfies the first constraint and achieves a utilization rate above the critical threshold is obtained. This includes detailed specifications for film cutting, positioning, and use to ensure optimal film utilization during the coating process. Based on the film utilization scheme and the spatial positioning points of the injection-molded finished product, precise coaxial control and limit are applied to the injection-molded finished product, coating mechanism components, and pre-coated film. This ensures precise alignment of all components during the coating process, preventing film waste and misalignment. Combining the results of the film utilization scheme and coaxial control limit, a dynamic limit strategy can be determined. This strategy will be implemented throughout the entire product lamination process, dynamically adjusting the limiting methods and parameters according to actual conditions to ensure the smooth progress of the lamination process and the efficient utilization of the film.

[0028] Furthermore, this application also includes: Identify the second constraint condition, perform an interval analysis between the coating and curing operations, and determine the operation interval; Combined with the curing decision-maker, non-uniform temperature management decisions are made for curing temperature to determine the curing temperature control strategy. The temperature management standard is axial uniform distribution and stable longitudinal temperature change trend. The temperature change trend is determined based on the time sequence of the coating position. Based on the operation interval and the temperature control strategy, a curing strategy is determined; The non-uniform temperature management includes: Determine the trend of curing temperature control, wherein the trend is marked with temperature change nodes throughout the curing cycle; Based on the aforementioned trend, temperature distribution management decisions are made based on the initial curing time point.

[0029] Specifically, the second constraint is the critical parameter control constraint for material deformation. This includes the material properties, surface properties, and adhesive properties of the injection-molded finished product and the pre-coated film. Next, an analysis of the interval between the coating and curing operations is performed. This interval needs to ensure that the adhesive can flow sufficiently and be uniformly distributed between the two materials, while avoiding excessive waiting time that could lead to over-curing or adhesive failure. A suitable operating interval is determined. In conjunction with the curing decision-maker, decisions are made regarding the non-uniform temperature management of the curing temperature. The goal here is to ensure a uniform distribution and stable temperature change during curing to avoid material deformation and stress concentration caused by uneven or rapid temperature changes. The standard for temperature management is uniform axial distribution and stable longitudinal temperature change trend. Along the axial direction of the product, the temperature should remain uniform; while in the longitudinal direction, the temperature change trend should be stable and determined based on the time sequence of the coating position. By analyzing the temperature change nodes throughout the curing cycle, the trend of temperature control during curing is determined. These nodes identify the key points of temperature change during curing. Based on the above trends, decisions are made regarding the temperature distribution management at the initial curing time node. This includes determining parameters such as the initial curing temperature, heating rate, isothermal time, and cooling rate. The final curing strategy is formulated by integrating the operation intervals and temperature control strategies. This includes the time interval from the completion of the coating operation to the start of the curing operation, the curing temperature profile including the heating, isothermal and cooling stages, and other relevant parameters during the curing process.

[0030] Furthermore, this application also includes: Based on the operation interval, the limiting strategy and the curing temperature control strategy are cross-coordinated to determine the coating strategy; If the number of coatings is multiple, the interlayer interaction analysis of the pre-coated film is performed in combination with the adhesive characteristics to locate the interlayer influence characteristics. The interlayer influence characteristics are the differential characteristics between the injection-molded finished product and the pre-coated film layers, and between the injection-molded finished product and the pre-coated film layers. Based on the interlayer influence characteristics, the coating strategy is adjusted to determine a multilayer coating strategy.

[0031] Specifically, a cross-coordination strategy is employed between the positioning and curing temperature control strategies. During the lamination process, it is crucial to ensure precise film positioning to meet geometric and utilization requirements, while simultaneously ensuring curing occurs within appropriate intervals to achieve optimal material properties. This cross-coordination allows for the development of a preliminary lamination strategy, encompassing detailed specifications for each stage, including film cutting, positioning, lamination, positioning, and curing. If multiple layers are involved, interlayer interactions require special consideration. In this case, an interlayer interaction analysis of the pre-coated film must be conducted, taking into account the adhesive's characteristics. The choice of adhesive directly impacts interlayer bond strength and stability. Analysis can pinpoint interlayer influence characteristics, namely, the differentiated characteristics between the injection-molded finished product and the pre-coated film layers, as well as between the pre-coated film layers themselves. These characteristics may include bond strength, coefficient of thermal expansion, and material hardness. Based on these interlayer influence characteristics, adjustments to the preliminary lamination strategy are necessary. This includes adjusting the adhesive selection, changing the film stacking sequence, and optimizing curing temperature and time. The goal of the adjustment is to ensure the bonding strength and stability between the multilayer films while meeting the requirements of product performance and appearance. The adjusted film-coating strategy will become the final multilayer film-coating strategy, guiding the entire multilayer film-coating process and ensuring that each film layer is precisely covered on the injection-molded finished product and that good adhesion is formed between the layers.

[0032] Furthermore, step S7 of this application also includes: The film coating monitoring data is transmitted back, and the deviation of the film coating monitoring data is measured to determine the deviation characteristics; Set an error threshold, and based on the error threshold, determine whether the deviation feature exceeds the limit, and determine the result of the limit exceedance determination; Based on the over-limit determination result, film coating feedback control is performed in conjunction with the digital feedback device, wherein the digital feedback device is configured with error self-adjustment rules.

[0033] Specifically, during the coating process, various sensors collect real-time monitoring data related to coating, such as temperature, pressure, and film position. This data is transmitted back to the control system for analysis and processing. The transmitted coating monitoring data is compared with preset standard values ​​or historical data to calculate the deviation. These deviations are analyzed to determine their characteristics, such as magnitude, direction, and trend. A reasonable error threshold is set based on the requirements of the coating process and product quality standards. The calculated deviation is compared with the error threshold to determine if it exceeds the limit. If the deviation exceeds the error threshold, it is considered an over-limit. Based on the over-limit determination result, corresponding measures are taken. If an over-limit is determined, immediate adjustment is required to correct the deviation. The over-limit determination result is input into the digital feedback unit. For control errors, such as deviations caused by equipment service conditions, error correction and feedback adjustment are performed based on the digital feedback unit. If the deviation is an abnormal over-limit, it indicates possible external causes, malfunctions, or other factors; contingency plans are implemented to avoid interruptions or quality anomalies; simultaneously, early warnings are issued for source tracing and management. These instructions are sent to the laminating equipment to adjust parameters such as temperature, pressure, and speed, thereby correcting deviations and bringing the laminating process back to normal.

[0034] Furthermore, this application also includes: If the result of the over-limit determination is negative, the system control error is calibrated in conjunction with the digital feedback device, and one-dimensional feedback regulation is performed in response to the film coating control system. If the result of the over-limit determination is yes, the target feedback plan is matched and an alarm is issued by traversing the control plan library. Based on the digital feedback device, two-dimensional feedback control is performed in response to the film covering control system.

[0035] Specifically, if the over-limit judgment result is negative, meaning the current deviation is within the normal range but there may still be some system control error, then system control error calibration is performed using a digital feedback device. This includes fine-tuning the system parameters to reduce the deviation between the actual output and the expected output. After calibration, the coating control system is responded to through one-dimensional feedback control. One-dimensional feedback control mainly refers to adjusting one or a few key parameters of the system based on the current deviation value to make the system output closer to the expected value. If the over-limit judgment result is positive, it indicates that the current deviation has exceeded the acceptable range, requiring more urgent and comprehensive control measures. At this time, the control plan library is traversed to find a target feedback plan that matches the target deviation characteristics. Once a matching plan is found, the system will issue an alarm to notify the operator of the current abnormal situation. Next, based on the digital feedback device, two-dimensional feedback control is performed on the coating control system. Two-dimensional feedback control refers to simultaneously adjusting multiple system parameters to quickly bring the system state back to the normal range.

[0036] In summary, the coating control method for injection-molded finished products provided in this application has the following technical advantages: By reading the first characteristic of the injection-molded finished product and the film characteristics of the pre-coated film, the first characteristic includes geometric characteristics, material characteristics, and surface characteristics; based on the first characteristic and the film characteristics, control constraints are determined; the underlying control mechanism of the injection molding machine is read, and combined with the control constraints, a limit decision-maker and a curing decision-maker are trained to integrate and collaboratively generate a coating decision model; coating quality standards and coating quantity are identified, and coating scenario factors are fed back. Combined with the coating decision model, the decision-makers are independently analyzed and verified, and individual decision schemes are interactively integrated to determine the coating strategy, wherein the coating strategy has hierarchical stages. The method identifies that the number of coating layers is one or more; transmits the coating strategy to the coating control system to execute the full-cycle coating control of the coating machine; constructs a control plan library for dynamic coating and establishes a communication connection between the control plan library, the digital feedback device, and the coating control system; synchronously monitors the coating process and manages the coating control in conjunction with the digital feedback device. This effectively solves the technical problem that the existing technology does not adequately consider the comprehensive characteristics of injection-molded finished products and films, resulting in a lack of targeted and precise coating strategies, which further affects the coating quality and production efficiency. This achieves refined control of the coating process and improves product quality and production efficiency.

[0037] Example 2 Based on the coating control method for injection-molded finished products described in the foregoing embodiments, and using the same inventive concept, this application also provides a coating control device for injection-molded finished products. Please refer to the appendix. Figure 2 The device includes: Finished product characteristic reading module 11 is used to read the first characteristic of the injection molded finished product and the film characteristics of the pre-coated film. The first characteristic includes geometric characteristics, material characteristics and surface characteristics. The constraint determination module 12 is used to determine control constraint conditions based on the first characteristic and the thin film characteristic; The decision model acquisition module 13 is used to read the underlying control mechanism of the injection molding machine, and in combination with the control constraints, train the limit decision-maker and the solidification decision-maker to integrate and collaboratively generate the coating decision model. The coating strategy acquisition module 14 is used to identify the coating quality standards and the number of coating layers, and to transmit coating scenario factors back. It combines the coating decision model to perform independent analysis and verification of the decision-maker, interactively integrates single decision schemes, and determines the coating strategy. The coating strategy has hierarchical stage identifiers, and the number of coating layers is one or more layers. The film coating control module 15 is used to transmit the film coating strategy to the film coating control system and execute the full-cycle film coating control of the film coating machine. The contingency plan library construction module 16 is used to construct a control contingency plan library for dynamic film covering and to establish a communication connection between the control contingency plan library, the digital feedback device and the film covering control system. The control and management module 17 is used to synchronously monitor the film covering and to control and manage the film covering in conjunction with the digital feedback device.

[0038] Furthermore, the constraint determination module 12 in the device is also used for: Identify the geometric characteristics of the injection-molded finished product and determine key spatial positioning points; Identify the film size based on the film characteristics, and determine the first constraint condition based on the spatial positioning point and the film utilization rate, wherein the film utilization rate must be higher than a critical threshold standard; Based on material properties, surface properties, and adhesive properties, a second constraint condition is determined, wherein the material properties include the injection-molded finished product and the pre-coated film, and the second constraint condition is a critical parameter control constraint for measuring material deformation; The control constraints are determined based on the first constraint and the second constraint.

[0039] Furthermore, the device also includes a dynamic policy acquisition module, which is used for: Identify the first constraint condition, combine it with the limit decision-maker, perform film limit optimization based on film utilization rate, and determine the film utilization scheme, wherein the optimization criteria are positive iteration and negative regression; Based on the aforementioned film utilization scheme, the injection-molded finished product, the film coating mechanism, and the pre-coated film are coaxially controlled and limited according to the spatial positioning point to determine the limiting strategy. The limiting strategy is a dynamic strategy for the entire film coating cycle of the finished product.

[0040] Furthermore, the device also includes a curing strategy acquisition module, which is used for: Identify the second constraint condition, perform an interval analysis between the coating and curing operations, and determine the operation interval; Combined with the curing decision-maker, non-uniform temperature management decisions are made for curing temperature to determine the curing temperature control strategy. The temperature management standard is axial uniform distribution and stable longitudinal temperature change trend. The temperature change trend is determined based on the time sequence of the coating position. Based on the operation interval and the temperature control strategy, a curing strategy is determined; The non-uniform temperature management includes: Determine the trend of curing temperature control, wherein the trend is marked with temperature change nodes throughout the curing cycle; Based on the aforementioned trend, temperature distribution management decisions are made based on the initial curing time point.

[0041] Furthermore, the device also includes a multi-layer coating strategy acquisition module, which is used for: Based on the operation interval, the limiting strategy and the curing temperature control strategy are cross-coordinated to determine the coating strategy; If the number of coatings is multiple, the interlayer interaction analysis of the pre-coated film is performed in combination with the adhesive characteristics to locate the interlayer influence characteristics. The interlayer influence characteristics are the differential characteristics between the injection-molded finished product and the pre-coated film layers, and between the injection-molded finished product and the pre-coated film layers. Based on the interlayer influence characteristics, the coating strategy is adjusted to determine a multilayer coating strategy.

[0042] Furthermore, the control and management module 17 in the device is also used for: The film coating monitoring data is transmitted back, and the deviation of the film coating monitoring data is measured to determine the deviation characteristics; Set an error threshold, and based on the error threshold, determine whether the deviation feature exceeds the limit, and determine the result of the limit exceedance determination; Based on the over-limit determination result, film coating feedback control is performed in conjunction with the digital feedback device, wherein the digital feedback device is configured with error self-adjustment rules.

[0043] Furthermore, the device also includes a two-dimensional feedback control module, which is used for: If the result of the over-limit determination is negative, the system control error is calibrated in conjunction with the digital feedback device, and one-dimensional feedback regulation is performed in response to the film coating control system. If the result of the over-limit determination is yes, the target feedback plan is matched and an alarm is issued by traversing the control plan library. Based on the digital feedback device, two-dimensional feedback control is performed in response to the film covering control system.

[0044] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Figure 1The coating control method and specific examples for injection-molded finished products in Embodiment 1 are also applicable to the coating control device for injection-molded finished products in this embodiment. Through the foregoing detailed description of the coating control method for injection-molded finished products, those skilled in the art can clearly understand the coating control device for injection-molded finished products in this embodiment. Therefore, for the sake of brevity, it will not be described in detail here. As for the device disclosed in the embodiments, since it corresponds to the method disclosed in the embodiments, the description is relatively simple; relevant details can be found in the method section.

[0045] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0046] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of this application and its equivalents, this application also intends to include such modifications and variations.

Claims

1. A method for controlling the coating of injection-molded finished products, characterized in that, The method includes: Read the first characteristics of the injection-molded finished product and the film characteristics of the pre-coated film, wherein the first characteristics include geometric characteristics, material characteristics and surface characteristics; Based on the first characteristic and the thin film characteristic, the control constraints are determined; The underlying control mechanism of the injection molding machine is read, and the control constraints are combined to train the limit decision-maker and the solidification decision-maker, and then the coating decision model is generated through integration and collaboration. Identify the coating quality standards and the number of coating layers, and return the coating scenario factors. Combine the coating decision model to conduct independent analysis and verification of the decision-maker, interactively integrate single decision schemes, and determine the coating strategy. The coating strategy has hierarchical stage identifiers, and the number of coating layers is one or more layers. The coating strategy is transmitted to the coating control system to execute the full-cycle coating control of the coating machine; Construct a control plan library for dynamic film coating, and establish a communication connection between the control plan library, the digital feedback device, and the film coating control system; Simultaneous monitoring of film coating is performed, and film coating control and management are carried out in conjunction with the digital feedback device. The step of determining the control constraints based on the first characteristic and the thin film characteristics includes: Identify the geometric characteristics of the injection-molded finished product and determine key spatial positioning points; Identify the film size based on the film characteristics, and determine the first constraint condition based on the spatial positioning point and the film utilization rate, wherein the film utilization rate must be higher than a critical threshold standard; Based on material properties, surface properties, and adhesive properties, a second constraint condition is determined, wherein the material properties include the injection-molded finished product and the pre-coated film, and the second constraint condition is a critical parameter control constraint for measuring material deformation; The control constraints are determined based on the first constraint and the second constraint. The independent analysis of the decision-maker, combined with the aforementioned film-covering decision model, includes: Identify the first constraint condition, combine it with the limit decision-maker, perform film limit optimization based on film utilization rate, and determine the film utilization scheme, wherein the optimization criteria are positive iteration and negative regression; In conjunction with the aforementioned film utilization scheme, the injection-molded finished product, the film coating mechanism, and the pre-coated film are coaxially controlled and limited based on the spatial positioning points to determine the limiting strategy. The limiting strategy is a dynamic strategy for the entire film coating cycle of the finished product. The independent analysis of the decision-maker, combined with the aforementioned film-covering decision model, includes: Identify the second constraint condition, perform an interval analysis between the coating and curing operations, and determine the operation interval; Combined with the curing decision-maker, non-uniform temperature management decisions are made for curing temperature to determine the curing temperature control strategy. The temperature management standard is axial uniform distribution and stable longitudinal temperature change trend. The temperature change trend is determined based on the time sequence of the coating position. Based on the operation interval and the temperature control strategy, a curing strategy is determined; The non-uniform temperature management includes: Determine the trend of curing temperature control, wherein the trend is marked with temperature change nodes throughout the curing cycle; Based on the aforementioned trend, temperature distribution management decisions are made based on the initial curing time point.

2. The method as described in claim 1, characterized in that, The interactive fusion single-item decision-making scheme includes: Based on the operation interval, the limiting strategy and the curing temperature control strategy are cross-coordinated to determine the coating strategy; If the number of coatings is multiple, the interlayer interaction analysis of the pre-coated film is performed in combination with the adhesive characteristics to locate the interlayer influence characteristics. The interlayer influence characteristics are the differential characteristics between the injection-molded finished product and the pre-coated film layers, and between the injection-molded finished product and the pre-coated film layers. Based on the interlayer influence characteristics, the coating strategy is adjusted to determine a multilayer coating strategy.

3. The method as described in claim 1, characterized in that, The method of combining the digital feedback device for film coating control management includes: The film coating monitoring data is transmitted back, and the deviation of the film coating monitoring data is measured to determine the deviation characteristics; Set an error threshold, and based on the error threshold, determine whether the deviation feature exceeds the limit, and determine the result of the limit exceedance determination; Based on the over-limit determination result, film coating feedback control is performed in conjunction with the digital feedback device, wherein the digital feedback device is configured with error self-adjustment rules.

4. The method as described in claim 3, characterized in that, The coating feedback control is performed in conjunction with the digital feedback device, including: If the result of the over-limit determination is negative, the system control error is calibrated in conjunction with the digital feedback device, and one-dimensional feedback regulation is performed in response to the film coating control system. If the result of the over-limit determination is yes, the target feedback plan is matched and an alarm is issued by traversing the control plan library. Based on the digital feedback device, two-dimensional feedback control is performed in response to the film covering control system.

5. A film coating control device for injection-molded finished products, characterized in that, The apparatus for carrying out the step of the method according to any one of claims 1 to 4, comprising: The finished product characteristic reading module is used to read the first characteristic of the injection-molded finished product and the film characteristics of the pre-coated film. The first characteristic includes geometric characteristics, material characteristics and surface characteristics. A constraint determination module is used to determine control constraints based on the first characteristic and the thin film characteristic; The decision model acquisition module is used to read the underlying control mechanism of the injection molding machine, combine it with the control constraints, train the limit decision-maker and the solidification decision-maker, and integrate and collaboratively generate the coating decision model. The coating strategy acquisition module is used to identify coating quality standards and coating quantity, and to return coating scenario factors. It combines the coating decision model to perform independent analysis and verification of the decision-maker, interactively integrates single decision schemes, and determines the coating strategy. The coating strategy has hierarchical stage identifiers, and the coating quantity is one or more layers. A film coating control module is used to transmit the film coating strategy to the film coating control system and execute the full-cycle film coating control of the film coating machine; A contingency plan library construction module is used to construct a control contingency plan library for dynamic film covering and to establish a communication connection between the control contingency plan library, the digital feedback device and the film covering control system. The control and management module is used to synchronously monitor the film covering and to control and manage the film covering in conjunction with the digital feedback device.

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