Sponge forming machine, system and method

Abstract

The sponge forming machine comprises a feeding mechanism used for conveying an erected sponge blank into a forming mechanism, and the forming mechanism comprises a cotton clamping assembly used for fixing and rotating the erected sponge blank, a grinding assembly used for grinding the peripheral face of the rotating sponge blank and a dust suction assembly used for adsorbing grinding dust; the discharging mechanism is used for outputting the polished sponge into a finished product box; the sponge size calling module is used for calling the size data of the sponge blank and the size data of the sponge body; the three-dimensional construction module is used for constructing a blank model and a finished product model; the to-be-ground quantity calculation module is used for calculating the volume between the boundary line of the blank model and the boundary line of the finished product model as the to-be-ground quantity; the device has the advantages that the air suction speed rate can be flexibly and accurately matched according to the actual situation, the grinding efficiency can be guaranteed, the fly ash can be efficiently collected, and environmental pollution is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of sponge processing, and in particular to a sponge forming machine, system and method. Background Art

[0002] In the field of sponge processing, with the continuous growth of the diversified demands of various industries for sponge products, the requirements for the precision and personalization of sponge forming processing are becoming increasingly strict. Traditional sponge forming processing equipment and processes have many defects and are difficult to meet the diverse requirements of customers for sponge materials and sizes. On the one hand, most equipment cannot accurately adapt to sponge materials with different characteristics, resulting in problems such as sponge deformation and high loss rate during the grinding process, greatly increasing the production cost. On the other hand, when dealing with the diverse shape requirements of customers, general grinding wheels are difficult to complete the grinding of complex shapes, and the matching degree between customized grinding wheels and equipment is poor, resulting in low processing efficiency and uneven product quality.

[0003] In addition, traditional equipment has serious deficiencies in system integration. The feeding, forming, conveying and other links are independent of each other and lack effective coordination. This not only results in a large floor area of the equipment, but also poor connection between each link, often causing jams, greatly affecting the overall production efficiency. These problems seriously restrict the development of the sponge processing industry and also limit the application expansion of sponge products in more fields. Moreover, during the sponge grinding process, the treatment of fly ash is poor, easily causing fly ash to disperse in the grinding area, which has a greater impact on the processing environment. Summary of the Invention

[0004] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a sponge forming machine, system and method.

[0005] The present invention solves its technical problems by adopting the following technical solutions:

[0006] A sponge forming machine includes a feeding mechanism, a discharging mechanism and at least one set of forming mechanisms. The feeding mechanism is used to convey the erected sponge blank into the forming mechanism. The forming mechanism includes a sponge clamping component, a grinding component and a dust suction component. The sponge clamping component is used to fix and rotate the erected sponge blank. The grinding component is used to grind the outer peripheral surface of the rotating sponge blank. The dust suction component is used to adsorb the dust generated during grinding. The discharging mechanism is used to output the ground sponge body into the finished product box.

[0007] Further, the feeding mechanism includes a feeding channel, the feeding channel passes through the forming mechanism and is connected to the discharging channel of the discharging mechanism, and a plurality of fixing seats moving along the feeding channel are arranged in the feeding channel.

[0008] Further, the fixing seat includes two groups of supporting members, and the two groups of supporting members respectively act on the outer peripheral surface of the erected sponge blank.

[0009] Further, the cotton sandwich component includes a first driving member, a second driving member, a third driving member and two sets of clamping wheels. A through hole is provided in the feeding channel located in the forming mechanism. The two sets of clamping wheels are respectively located on both sides of the through hole. The first driving member is used to drive the two sets of clamping wheels to move towards or away from each other. The second driving member is used to synchronously drive the two sets of clamping wheels to move in the vertical direction. The third driving member is used to drive any one set of clamping wheels to rotate.

[0010] Further, the dust suction component includes a dust suction hood and a dust suction pipe. The dust suction pipe is connected to the dust suction hood. A grinding opening is provided below the dust suction hood. The grinding component includes a grinding wheel. The grinding wheel is located inside the dust suction hood. The dust suction hood and the grinding wheel can move synchronously so that the grinding opening of the dust suction hood is aligned with the through hole below.

[0011] A sponge forming system includes

[0012] a sponge size retrieval module that retrieves the size data of the sponge blank and the size data of the sponge body. The size data of the sponge blank includes the length, width and thickness of the sponge blank. The size data of the sponge body includes the diameter and thickness of the sponge body;

[0013] a three-dimensional construction module that constructs a three-dimensional coordinate system with the center point of the sponge blank as the origin, and constructs a three-dimensional model in the three-dimensional coordinate system as the blank model according to the size data of the sponge blank. Similarly, a three-dimensional model is constructed as the finished product model according to the size data of the sponge body, and the finished product model is mapped in the blank model based on the origin and thickness;

[0014] a to-be-ground amount calculation module that obtains the boundary line of the blank model and the boundary line of the finished product model in the three-dimensional coordinate system, and calculates the volume between the boundary line of the blank model and the boundary line of the finished product model as the to-be-ground amount;

[0015] an air suction rate matching module that retrieves the grinding wheel speed, the clamping wheel speed, the blank top pressing speed and the dust suction pipe diameter, calculates the fly ash output per second through a first formula according to the grinding wheel speed, the clamping wheel speed, the blank top pressing speed and the to-be-ground amount, and then calculates the dust suction power through a second formula according to the fly ash output per second and the dust suction pipe diameter.

[0016] Further, the first formula is configured as:

[0017]

[0018] where Q is the fly ash output per second, λ is the dynamic friction coefficient, V is the to-be-ground amount, ω m is the grinding wheel speed, ω j is the clamping wheel speed, v pis the blank pressing speed, and t is the integral variable normalized time parameter;

[0019] The second formula is configured as:

[0020]

[0021] Wherein, P is the dust suction power, d is the diameter of the dust suction pipe, erf is the error function, and ln is the natural logarithm function.

[0022] Further, a vision camera is provided on one side of the dust suction hood, and a vision feedback module is further included. The image collected by the vision camera on one side of the dust suction hood is obtained as the image to be analyzed. Whether there is dust falling outside the grinding port of the dust suction hood is judged according to the image to be analyzed. If so, a dust suction power increase instruction or a blank pressing speed decrease instruction is output.

[0023] Further, a grinding pressure adjustment module is further included. When the dust suction power is greater than or equal to the preset power threshold, the preset power threshold is used as the current dust suction power, and the blank pressing speed is inversely deduced through the second formula and the first formula, and the inversely deduced blank pressing speed is used as the actual blank pressing speed.

[0024] A sponge forming method includes

[0025] Sponge size retrieval step, retrieving the size data of the sponge blank and the size data of the sponge body. The size data of the sponge blank includes the length, width, and thickness of the sponge blank, and the size data of the sponge body includes the diameter and thickness of the sponge body;

[0026] Three-dimensional construction step, constructing a three-dimensional coordinate system with the center point of the sponge blank as the origin, and constructing a three-dimensional model in the three-dimensional coordinate system as the blank model according to the size data of the sponge blank. Similarly, a three-dimensional model is constructed with the size data of the sponge body as the finished product model, and the finished product model is mapped in the blank model based on the origin and thickness;

[0027] Amount to be ground calculation step, obtaining the boundary line of the embryo model and the boundary line of the finished product model in the three-dimensional coordinate system, and calculating the volume between the boundary line of the embryo model and the boundary line of the finished product model as the amount to be ground;

[0028] Air suction rate matching step, retrieving the grinding wheel speed, the clamping wheel speed, and the diameter of the dust suction pipe, calculating the fly ash production per second through the first formula according to the grinding wheel speed, the clamping wheel speed, and the amount to be ground, and then calculating the dust suction power through the second formula according to the fly ash production per second and the diameter of the dust suction pipe.

[0029] The advantages and positive effects of the present invention are: 1. The feeding mechanism, the molding mechanism and the discharging mechanism are closely coordinated, the feeding channel and the discharging channel are seamlessly connected, and the fixed seat cooperates with the stable movement along the feeding channel to realize continuous and stable transportation of the sponge blank, greatly reducing the material waiting time, and effectively improving the overall processing efficiency. The upright sponge blank is clamped and rotated at the center point through the cotton clamping component, which is convenient for grinding the outer peripheral surface of the sponge blank to the specified requirements. The dust collection component is arranged to timely absorb the dust generated during the grinding process, prevent dust from flying, improve the working environment, and reduce the impact on the health of the operator.

[0030] 2. Traditional equipment causes a bad processing environment due to the scattering of fly ash, which seriously affects the health of workers and the cleanliness of the working environment. However, this solution uses the suction rate matching module to calculate the fly ash production and dust suction power per second based on multiple parameters. It can flexibly and accurately match the suction rate according to actual conditions, which can not only ensure the grinding efficiency, but also efficiently collect fly ash and reduce environmental pollution. This allows the equipment to flexibly and efficiently adjust the suction rate according to actual working conditions, greatly reduce the dispersion of fly ash, significantly improve the processing environment, protect the health of workers, and at the same time improve the controllability and production efficiency of the grinding process, and optimize the overall processing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is the overall structural diagram of the present invention;

[0032] Figure 2 It is a structural diagram of the forming mechanism in the present invention;

[0033] Figure 3 It is a system flow chart of the present invention.

[0034] Additional markings: 1. Feeding mechanism; 11. Feeding channel; 12. Dual-channel feeding assembly; 121. Material shifting member; 2. Forming mechanism; 3. Discharging mechanism; 31. Cotton clamping assembly; 311. First driving member; 312. Second driving member; 313. Third driving member; 314. Clamping wheel; 32. Grinding assembly; 321. Grinding wheel; 33. Dust collection assembly; 331. Dust collection hood; 332. Dust collection tube; 4. Sponge blank; 5. Transparent panel. DETAILED DESCRIPTION

[0035] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0036] It should be noted that when a component is referred to as "fixed to" another component, it can be directly on the other component or there may be an intermediate component. When a component is considered to be "connected to" another component, it can be directly connected to the other component or there may be an intermediate component at the same time. When a component is considered to be "disposed on" another component, it can be directly disposed on the other component or there may be an intermediate component at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.

[0037] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field to which this invention belongs. The terms used herein in the specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.

[0038] The following further details the embodiments of the present invention with reference to the accompanying drawings:

[0039] Since the current sponge processing equipment has low grinding accuracy and serious deficiencies in system integration, the feeding, forming, conveying and other links are independent of each other and lack effective coordination. This not only results in a large floor area of the equipment, but also poor connection between each link and frequent jams, greatly affecting the overall production efficiency. Therefore, the present invention designs this sponge forming machine, as Figure 1 shown, which includes a feeding mechanism, a discharging mechanism and at least one set of forming mechanisms (in the present invention, there are two sets of forming mechanisms for adapting to double-channel feeding);

[0040] The feeding mechanism includes a double-channel feeding component and a feeding channel. The feeding channel passes through the forming mechanism and is connected to the discharging channel of the discharging mechanism. The double-channel feeding component includes a conveyor belt and a material pushing member. A double channel formed by a partition is provided in the conveying direction of the conveyor belt. The discharging ends of the double channels are located above the conveying channel. In addition, several fixed seats moving along the feeding channel are provided in the feeding channel. The material pushing member is used to push the sponge blanks stacked upright in the double channels one by one into the fixed seats in the feeding channel to prevent the upright sponge blanks from tilting or falling over. In the present invention, the feeding mechanism, the forming mechanism and the discharging mechanism cooperate closely, the feeding channel and the discharging channel are seamlessly connected, and with the stable movement of the fixed seats along the feeding channel, the continuous and stable conveying of the sponge blanks is realized, greatly reducing the material waiting time and effectively improving the overall processing efficiency. In the double-channel feeding component, the conveyor belt and the material pushing member work together to push the stacked sponge blanks one by one into the feeding mechanism, further improving the feeding efficiency and realizing batch production.

[0041] Among them, the fixed seat includes two groups of support members, and the two groups of support members act on the outer peripheral surface of the erected sponge blank respectively. The width of the feeding channel is the same as that of the sponge blank. At this time, the sponge blank falling into the fixed seat is just stuck, but the requirement for the falling accuracy is relatively high. Therefore, the width of the feeding channel can be slightly larger than that of the sponge blank. At this time, when the sponge blank is a square material, the support member is an inclined plate, and the inclined plates of the two groups of support members are arranged oppositely to form an angle, usually 90°, which matches one corner of the square material and can fix the square material. When the sponge blank is a circular material, the support member is an arc-shaped plate, and the arc-shaped plates of the two groups of support members are arranged oppositely to form an arc, which can just match the circular material and is convenient for limiting the circular material to prevent the sponge blank from rolling and further ensuring the grinding accuracy.

[0042] As Figure 2 shown, the forming mechanism includes a cotton clamping assembly, a grinding assembly and a dust suction assembly. The cotton clamping assembly is used to fix and rotate the erected sponge blank, the grinding assembly is used to grind the outer peripheral surface of the rotating sponge blank, the dust suction assembly is used to adsorb the dust generated during grinding, and the discharging mechanism is used to output the ground sponge body into the finished product box. Specifically, the cotton clamping assembly includes a first driving member, a second driving member, a third driving member and two groups of clamping wheels. A through hole is provided in the feeding channel located in the forming mechanism. The feeding channel is composed of two long plates, and the through hole is "U"-shaped and penetrates through the two long plates. The two groups of clamping wheels are respectively located on both sides of the "U"-shaped through hole. The first driving member is used to drive the two groups of clamping wheels to move towards or away from each other. The two groups of clamping wheels and the corresponding first driving member are all installed on a plate. The second driving member is used to synchronously drive the two groups of clamping wheels to move in the vertical direction, that is, the second driving member drives this plate to move in the vertical direction. The third driving member is used to drive any one group of clamping wheels to rotate. Among them, the first driving member and the second driving member can be cylinders or screw members, and the third driving member is a motor.

[0043] The three driving members in the cotton clamping assembly cooperate with each other to accurately control the actions of the clamping wheels. The first driving member makes the clamping wheels tightly fix the sponge blank. The second driving member realizes the flexible adjustment of the clamping wheels in the vertical direction. The third driving member drives the clamping wheels to rotate, ensuring that the sponge blank remains stable and can rotate in all directions during the grinding process. Cooperating with the grinding wheel of the grinding assembly, the outer peripheral surface of the sponge blank can be accurately ground to meet the requirements of high-precision processing.

[0044] The dust collection component includes a dust collection hood and a dust collection pipe. The dust collection pipe is connected to the dust collection hood. There is a grinding port under the dust collection hood. The grinding component includes a grinding wheel. The grinding wheel is located inside the dust collection hood and can adsorb the generated dust in time during the grinding process, prevent the dust from flying, improve the working environment, reduce the impact on the health of the operators, and meet the requirements of environmental protection production. The dust collection hood and the grinding wheel can move synchronously to ensure that the grinding port is always aligned with the through port, improve the dust collection efficiency, minimize the dust residue to the greatest extent, and the dust collection hood and the grinding wheel can move synchronously so that the grinding port of the dust collection hood is aligned with the through port below.

[0045] In addition, one side panel of the dust collection hood is a transparent panel, and the operator can directly observe the grinding situation, discover problems in time and make adjustments, reducing the operation difficulty. The overall structure of the equipment is reasonably designed, the functions of each component are clear, which is convenient for installation, debugging and maintenance, reduces the equipment maintenance cost, and prolongs the service life of the equipment.

[0046] Working principle: When the fixing seat with the sponge blank moves to the position of the through port and stops, the clamping wheels on both sides move towards each other to clamp both sides of the sponge blank. Under normal circumstances, the clamping wheels act on the center point of the sponge blank. After the two clamping wheels clamp the sponge blank, they move upward to under the dust collection hood so that part of the sponge blank enters the grinding port and contacts the grinding wheel for grinding. During the grinding process, one of the clamping wheels rotates to drive the sponge blank to rotate to achieve the grinding of the entire sponge blank. After the grinding is completed, the clamping wheels move downward to place the sponge body on the fixing seat and grind the next sponge blank.

[0047] Due to the fact that the processing environment of traditional equipment is poor due to the flying ash, which seriously affects the health of workers and the cleanliness of the working environment, this sponge forming system is designed in the present invention, as Figure 3 shown, including

[0048] A sponge size retrieval module retrieves the size data of the sponge blank and the size data of the sponge body. The size data of the sponge blank includes the length, width and thickness of the sponge blank (L, W, T are the length, width and thickness of the blank). Usually, the shape of the sponge blank includes a cube, a cylinder, etc. The sponge body is formed by grinding the outer peripheral surface of the sponge blank. The size data of the sponge body includes the diameter and thickness of the sponge body (D, h are the diameter and thickness of the finished product).

[0049] A three-dimensional construction module constructs a three-dimensional coordinate system with the center point of the sponge blank as the origin. Specifically, ①. Dynamic origin calibration: Obtain the surface point cloud of the sponge blank through laser scanning, and calculate the centroid coordinates (x c , y c , z c ) by using principal component analysis, and determine the geometric center as the origin with an accuracy of ±0.1 mm. This step is carried out before grinding this batch of sponge blanks; ②. Axial alignment optimization: Based on the maximum inertia axis in the length, width and thickness directions of the blank, establish an orthogonal basis (eL , e W , e T ) Ensure that the coordinate system is strongly correlated with the physical properties of the blank; ③. Coordinate scaling mechanism: Introduce a normalized coordinate system Realize the unified mathematical expression of blanks of different sizes; and construct a three-dimensional model in the three-dimensional coordinate system as the blank model according to the size data of the sponge blank, and also construct a three-dimensional model as the finished product model according to the size data of the sponge body, and map the finished product model into the blank model based on the origin and thickness.

[0050] Stock removal calculation module, obtain the boundary line of the blank model and the boundary line of the finished product model in the three-dimensional coordinate system, and calculate the volume between the boundary line of the blank model and the boundary line of the finished product model as the stock removal; among them, there are two calculation methods for calculating the stock removal. The calculation formula of the first method is configured as:

[0051] V = V 胚 - V 成 ;

[0052] Among them, V is the stock removal, V 胚 is the volume of the blank model, and V 成 is the volume of the finished product model;

[0053] The calculation formula of the second method is configured as:

[0054] V = ∫∫∫ Ω [H(f e (x, y, z)) - H(f p (x, y, z))]·dx·dy·dz;

[0055] Among them, V is the stock removal, H is the step function in the three-dimensional space, and f e (x, y, z) = 0 is the implicit equation of the blank model boundary. For example, if the blank is a cuboid, then L, W, T are the length, width, and thickness of the blank, n is the super-ellipsoid index (n = 2 for a standard cuboid), and f p (x, y, z) = 0 is the implicit equation of the finished product model boundary. For example, if the finished product is a cylindrical sponge body, then D, h are the diameter and thickness of the finished product, k is the end face curvature parameter, and Ω is the three-dimensional integral region defined by the blank bounding box.

[0056] Data example:

[0057] Assume that the blank is a cuboid with L×W×T = 10×8×5 cm, and the finished product is a cylinder with D = 6 cm and h = 3 cm. Take n = 2, k = 2: Blank equation: V ≈ 15.03 cm 3 .

[0058] An air suction rate matching module retrieves the grinding wheel speed, clamping wheel speed, blank top pressure speed, and the diameter of the dust suction pipe. It calculates the fly ash output per second through a first formula based on the grinding wheel speed, clamping wheel speed, blank top pressure speed, and the amount of material to be ground. The first formula is configured as:

[0059]

[0060] where Q is the fly ash output per second, that is, the volume of debris to be ground and sucked out per unit time; λ is the dynamic friction coefficient (dimensionless, a fixed value of 2.4), comprehensively reflecting the friction characteristics of the grinding wheel - blank contact surface, obtained through experimental calibration; V is the amount of material to be ground; ω m is the grinding wheel speed, with the clockwise direction defined as positive; ω j is the clamping wheel speed, with the counterclockwise direction defined as negative; v p is the blank top pressure speed, controlling the contact duration between the sponge blank and the grinding wheel; t is the integral variable normalization time parameter. According to actual processing requirements, the actual grinding time (10 seconds) can be compressed within the interval [0, 1] for integral modeling;

[0061] In addition, the reverse speed coupling effect: the superposition effect of reverse speed is expressed by ω m t + ω j t. The square term reflects the suppression of fly ash generation due to kinetic energy loss. The non - linear friction weight: |(ω m - ω j ) / max(ω m , ω j )| 1.7 quantifies the contribution of speed difference, and the 1.7 - power enhances the sensitivity of the high - differential speed area. The exponential decay modulation: simulates the dilution effect of the top pressure speed on fly ash. The larger v p , the shorter the grinding time, and the faster the fly ash concentration decays with time.

[0062] Data example:

[0063] Set ω m = 3000 rpm, ω j = - 1500 rpm, v p = 2 mm / s, V = 15 cm 3 ;

[0064] Synthetic speed: 3000t + (-1500t)=1500t;

[0065] Weight term calculation: |(3000 - (-1500)) / max(3000, 1500)| 1.7 ≈2.34;

[0066] Integral kernel function:

[0067] Numerical integration result:

[0068] Final Q value: Q = (2.4 × 15) / 10 × 0.0042 ≈ 1.52 cm 3 / s, meeting the requirement of processing 15 cubic centimeters within 10 seconds.

[0069] Then, calculate the dust suction power according to the fly ash production per second and the diameter of the dust suction pipe through the second formula, and the second formula is configured as:

[0070]

[0071] Wherein, P is the dust suction power, that is, the power of the air pump generating the dust suction negative pressure, d is the diameter of the dust suction pipe, which determines the air flow cross-sectional area and flow velocity distribution, erf is the error function, used to quantify the diffusion loss of fly ash particles in the high-speed air flow, ln is the natural logarithm function, which adjusts the non-linear relationship between the air flow resistance and the debris concentration in the pipeline;

[0072] In addition, where Q 3 term: reflects that the fly ash kinetic energy is proportional to the cube of the volume flow rate, πd 2 : corresponds to the pipeline cross-sectional area, restricting the flow velocity to be inversely proportional to the square of the diameter, erf(Q / 0.4d): describes the diffusion effect of fly ash under high-speed air flow. When Q / d > 0.4, the erf value approaches 1, indicating diffusion saturation. The logarithmic term ln(1 + 2Q / d 0.8 ): simulates the pipeline roughness and turbulent loss, d 0.8 reflects the weak attenuation characteristic of the pipe diameter on the boundary layer friction. The coefficient 15 is the calibrated comprehensive compensation coefficient. The function superposition: the error function dominates the power growth in the low flow rate area, and the logarithmic function suppresses the overshoot in the high flow rate area, realizing a smooth transition under all working conditions.

[0073] Data example:

[0074] Set: Q = 1.52 cm 3 / s, d = 5 cm;

[0075] Error function calculation: erf(1.52 / (0.4 × 5)) ≈ 0.717;

[0076] Logarithmic term calculation:

[0077] Dust suction power: Air pressure calculation, by back-calculating through P = Δp·Q / η. Assuming η = 60%, the air pressure Δp ≈ 0.48 MPa, meeting the requirements.

[0078] The advantages of the present invention are as follows: The fly ash production per second and the dust suction power are calculated based on multiple parameters, and the air suction rate can be flexibly and accurately matched according to the actual situation. It can not only ensure the grinding efficiency but also efficiently collect fly ash, reducing environmental pollution. This enables the device to flexibly and efficiently adjust the air suction rate according to the actual working conditions, greatly reducing the dispersion of fly ash, significantly improving the processing environment, ensuring the health of workers, while enhancing the controllability and production efficiency of the grinding process and optimizing the overall processing flow.

[0079] On one side of the dust suction hood, there is a vision camera (the vision camera integrates dual-channel imaging of near-infrared (850nm) and visible light, enhances the dust contrast through band fusion (weight ratio 0.6:0.4), and solves the problem of reflection interference). There is also a visual feedback module that acquires the image on one side of the dust suction hood collected by the vision camera as the image to be analyzed, and judges whether there is dust falling outside the grinding port of the dust suction hood according to the image to be analyzed. If so, it outputs an instruction to increase the dust suction power or an instruction to decrease the blank pressing speed.

[0080] There is also a grinding pressure adjustment module. When the dust suction power is greater than or equal to the preset power threshold, the preset power threshold is used as the current dust suction power, and the blank pressing speed is inversely deduced through the second formula and the first formula, and the inversely calculated blank pressing speed is used as the actual blank pressing speed.

[0081] Through the reverse drive of visual perception and physical model, the intelligent closed-loop control of dust suction power - grinding process is realized, reducing the dust escape rate of the traditional open-loop system from 15% to 2.1%, while ensuring the dual improvement of process stability and energy efficiency ratio.

[0082] For the sponge forming machine and forming system, a corresponding forming method is designed, including

[0083] Sponge size retrieval step: Retrieve the size data of the sponge blank and the size data of the sponge body. The size data of the sponge blank includes the length, width, and thickness of the sponge blank, and the size data of the sponge body includes the diameter and thickness of the sponge body.

[0084] Three-dimensional construction step: A three-dimensional coordinate system is constructed with the center point of the sponge blank as the origin, and a three-dimensional model is constructed in the three-dimensional coordinate system according to the size data of the sponge blank as the blank model. Similarly, a three-dimensional model is constructed with the size data of the sponge body as the finished product model, and the finished product model is mapped in the blank model based on the origin and thickness.

[0085] Amount to be ground calculation step: Obtain the boundary line of the embryo model and the boundary line of the finished product model in the three-dimensional coordinate system, and calculate the volume between the boundary line of the embryo model and the boundary line of the finished product model as the amount to be ground.

[0086] The air suction rate matching step: retrieve the grinding wheel speed, clamping wheel speed, and the diameter of the dust suction pipe. Calculate the fly ash output per second according to the grinding wheel speed, clamping wheel speed, and the amount of material to be ground through the first formula, and then calculate the dust suction power according to the fly ash output per second and the diameter of the dust suction pipe through the second formula.

[0087] It should be emphasized that the embodiments described in the present invention are illustrative rather than restrictive. Therefore, the present invention is not limited to the embodiments described in the specific implementation manners. Any other implementation manners obtained by those skilled in the art based on the technical solutions of the present invention also fall within the scope of protection of the present invention.

Claims

1. A sponge molding machine, characterized in that: It includes a feeding mechanism, a discharging mechanism and at least one set of forming mechanisms. The feeding mechanism is used to convey the erected sponge blank into the forming mechanism. The forming mechanism includes a cotton clamping assembly, a grinding assembly and a dust suction assembly. The cotton clamping assembly is used to fix and rotate the erected sponge blank. The grinding assembly is used to grind the outer peripheral surface of the rotating sponge blank. The dust suction assembly is used to adsorb the dust generated during grinding. The discharging mechanism is used to output the ground sponge body into a finished product box.

2. The sponge forming machine according to claim 1, wherein: The feeding mechanism includes a feeding channel which passes through the forming mechanism and is connected to the discharging channel of the discharging mechanism. A number of fixing seats moving along the feeding channel are arranged in the feeding channel.

3. The sponge forming machine according to claim 2, wherein: The fixing seat includes two groups of supporting members which respectively act on the outer peripheral surface of the erected sponge blank.

4. The sponge forming machine according to claim 3, wherein: The cotton clamping assembly includes a first driving member, a second driving member, a third driving member and two groups of clamping wheels. A through opening is provided in the feeding channel located inside the forming mechanism. The two groups of clamping wheels are respectively located on both sides of the through opening. The first driving member is used to drive the two groups of clamping wheels to move towards or away from each other. The second driving member is used to synchronously drive the two groups of clamping wheels to move in the vertical direction. The third driving member is used to drive any one group of clamping wheels to rotate.

5. The sponge forming machine according to claim 4, wherein: The dust suction assembly includes a dust suction hood and a dust suction pipe. The dust suction pipe is connected to the dust suction hood. A grinding opening is provided below the dust suction hood. The grinding assembly includes a grinding wheel which is located inside the dust suction hood. The dust suction hood and the grinding wheel can move synchronously so that the grinding opening of the dust suction hood is aligned with the through opening below.

6. A sponge forming system, such as the sponge forming machine according to any one of claims 1-5, characterized in that: Include A sponge size retrieval module which retrieves the size data of the sponge blank and the size data of the sponge body. The size data of the sponge blank includes the length, width and thickness of the sponge blank. The size data of the sponge body includes the diameter and thickness of the sponge body. A three-dimensional construction module which constructs a three-dimensional coordinate system with the center point of the sponge blank as the origin, and constructs a three-dimensional model in the three-dimensional coordinate system as a blank model according to the size data of the sponge blank. Similarly, a three-dimensional model is constructed as a finished product model according to the size data of the sponge body, and the finished product model is mapped into the blank model based on the origin and thickness. A to-be-ground amount calculation module which obtains the boundary line of the blank model and the boundary line of the finished product model in the three-dimensional coordinate system, and calculates the volume between the boundary line of the blank model and the boundary line of the finished product model as the to-be-ground amount. An air suction rate matching module which retrieves the grinding wheel rotation speed, the clamping wheel rotation speed, the blank pressing speed and the dust suction pipe diameter. According to the grinding wheel rotation speed, the clamping wheel rotation speed, the blank pressing speed and the to-be-ground amount, the fly ash output per second is calculated through a first formula, and then the dust suction power is calculated through a second formula according to the fly ash output per second and the dust suction pipe diameter.

7. The sponge forming system according to claim 6, wherein: The first formula is configured as: Where, Q is the fly ash production per second, λ is the dynamic friction coefficient, V is the amount to be ground, ω m is the grinding wheel speed, ω j is the clamping wheel speed, v p is the blank pressing speed, and t is the integral variable normalized time parameter; The second formula is configured as: Where P is the dust suction power, d is the dust suction pipe diameter, erf is the error function, and ln is the natural logarithm function.

8. The sponge forming system according to claim 7, wherein: A vision camera is provided on one side of the dust suction hood, and a vision feedback module is further included, which acquires the image on one side of the dust suction hood collected by the vision camera as the image to be analyzed, and judges whether there is dust falling outside the grinding port of the dust suction hood according to the image to be analyzed. If so, an instruction to increase the dust suction power or an instruction to decrease the blank pressing speed is output.

9. The sponge forming system according to claim 8, characterized in that: A grinding pressure adjustment module is further included. When the dust suction power is greater than or equal to the preset power threshold, the preset power threshold is used as the current dust suction power, and the blank pressing speed is inversely deduced through the second formula and the first formula, and the inversely deduced blank pressing speed is used as the actual blank pressing speed.

10. A sponge forming method, for the sponge forming machine according to any one of claims 1-5, characterized in that: Include A sponge size retrieval step of retrieving the size data of the sponge blank and the size data of the sponge body. The size data of the sponge blank includes the length, width and thickness of the sponge blank, and the size data of the sponge body includes the diameter and thickness of the sponge body; A three-dimensional construction step of constructing a three-dimensional coordinate system with the center point of the sponge blank as the origin, and constructing a three-dimensional model in the three-dimensional coordinate system according to the size data of the sponge blank as the blank model. Similarly, a three-dimensional model is constructed with the size data of the sponge body as the finished product model, and the finished product model is mapped in the blank model based on the origin and thickness; A to-be-ground amount calculation step of obtaining the boundary line of the embryo model and the boundary line of the finished product model in the three-dimensional coordinate system, and calculating the volume between the boundary line of the embryo model and the boundary line of the finished product model as the to-be-ground amount; A suction air rate matching step of retrieving the grinding wheel speed, the pinch wheel speed and the diameter of the dust suction pipe, calculating the fly ash output per second through the first formula according to the grinding wheel speed, the pinch wheel speed and the to-be-ground amount, and then calculating the dust suction power through the second formula according to the fly ash output per second and the diameter of the dust suction pipe.

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