Control method for top peg of internal mixer

Abstract

The invention relates to a control method for a top peg of an internal mixer, which comprises the following steps of: if a specific internal mixing combined action is detected to be executed currently, executing intelligent control on the position of the top peg, specifically, controlling the lifting of the top peg, and giving a simulation in-place signal in the process of executing the lifting of the top peg; after receiving the simulation in-place signal, the top peg stops lifting and prepares to execute the next specified internal mixing action in the current internal mixing combined action; wherein the lifting stopping position of the top peg is in front of the preset position. According to the scheme, the simulation in-place signal of in-place uplifting or in-place cleaning of the top peg can be intelligently given, time waste and energy waste caused by the adoption of the actual in-place signal of the top peg in the prior art are overcome, and the internal mixing auxiliary time can be shortened on the premise that the process quality can be guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of rubber production, and in particular to a control method for a top bolt on an internal mixer. Background Art

[0002] like Figure 1 As shown in the figure, the main working parts of the internal mixer include a mixing chamber, two rotors with ridges on the surface and rotating relative to each other, an upper ejector bolt, a lower ejector bolt, a drive system and a cooling system. The rotor is the core component of the internal mixer. With the cooperation of the upper ejector bolt, the lower ejector bolt and other equipment, the materials are dispersed and mixed through the rotor in the mixing chamber.

[0003] As a key component of the internal mixer, the ram plays a crucial role in compacting the material during mixing. Currently, the mainstream control method for internal mixer rams is hydraulic rams. This utilizes a servo valve to control pressure, offering fast response times and precise, stable pressure control. The ram automatically moves up and down during the mixing process to find a pressure equilibrium position, maintaining the set pressure value at all times, thus ensuring uniform mixing quality.

[0004] Generally speaking, the top bolt of an internal mixer has several positions, such as up, down, floating, and cleaning. During mixing, the top bolt is raised or lowered to a specific position based on process requirements to complete the mixing of the rubber compound. In actual production, when the top bolt reaches a specific position, such as the up position, a sensing signal is triggered, and the top bolt then executes the next pre-set action. However, some combined mixing process actions, such as "raising the top bolt to up position + lowering the top bolt" or "cleaning the top bolt + lowering the top bolt," do not require the top bolt to actually be in the up position or cleaning position. Consequently, in current mixing operations, there is no effective measure that can both ensure process quality and reduce auxiliary mixing time. Summary of the Invention

[0005] In order to solve the above problems, the purpose of the present invention is to provide a control method for the top bolt on the internal mixer, which improves the motion control of the top bolt on the internal mixer to improve the rubber mixing efficiency while ensuring the process quality.

[0006] A method for controlling a top bolt on an internal mixer comprises the following steps:

[0007] Based on a preset automatic mixing process, determining whether a specific mixing combination action is currently being performed, each specific mixing combination action includes two specified mixing actions that are consecutive in sequence, and the previous mixing action is to raise the top bolt to a preset position; the specific mixing combination action indicates that the top bolt is currently being raised for turning the rubber material;

[0008] If it is detected that a specific mixing combination action is currently being executed, the upper ejector bolt position intelligent control is executed, specifically:

[0009] Control the lifting of the ejector pin, and give a simulated in-position signal during the execution of the ejector pin lifting action. After receiving the simulated in-position signal, the ejector pin stops lifting and prepares to execute the next specified mixing action in the current mixing combination action; wherein, the stop lifting position of the ejector pin is before the preset position.

[0010] Preferably, during the process of lifting the ejector bolt, if the following conditions are met at the same time, a simulated in-position signal is given:

[0011] The displacement of the upper ejector bolt reaches the preset minimum value;

[0012] The pressure on the upper ram drops to zero;

[0013] The timing starts when the action of lifting the top bolt is started, and the timing reaches the preset delay time.

[0014] Preferably, different mixing combination actions are respectively set with corresponding delay times, and before determining whether the timing reaches the preset delay time, the method includes the following steps:

[0015] According to the combination of the currently executing mixing actions, the corresponding preset delay time is determined.

[0016] Preferably, the system further comprises a manual setting module for manually setting a preset minimum displacement of the upper ejector bolt and a preset delay time of the upper ejector bolt action within a preset range;

[0017] The controller obtains the time parameters set by the manual setting module and performs subsequent judgments based on the adjusted time parameters.

[0018] Preferably, the determining whether a specific refining combination action is currently being performed includes:

[0019] Determine whether the currently executed or required banburying action involves the action of raising the top bolt. If so, determine whether the next action to be executed in the planned sequence is to lower the top bolt. If so, determine that a specific banburying combination action is currently being executed.

[0020] Preferably, the specific banburying combination action includes firstly raising the top bolt to a preset upper position and then lowering the top bolt; and firstly raising the top bolt to a preset cleaning position and then lowering the top bolt.

[0021] Preferably, a first control switch is included, and after the controller receives a trigger signal from the first control switch, it stops using the intelligent control of the upper ejector pin position and executes the preset automatic mixing process sequence.

[0022] Preferably, it includes automatically recording various working parameters during the automatic mixing process, wherein the working parameters include the action time of the upper push bolt, and the action time of the upper push bolt includes the actual time when the upper push bolt is in place and the simulated time when the upper push bolt is in place, and the working parameters are presented on the user interaction interface.

[0023] Preferably, a work report is automatically generated after the mixing of a truckload of material is completed, and the work report includes the formulation time and the mixing time; wherein, the formulation time refers to the time required for one truckload of material, starting from the time when the rubber material is added, until the mixer discharge door is closed, and all the mixing actions of this truckload are completed; the mixing time refers to the time required for one truckload of material, starting from the time when the rubber material is added, until the mixer discharge door is opened.

[0024] Since the present application adopts the above-mentioned scheme, through program judgment, an analog in-position signal is intelligently given to indicate that the upper ejector bolt is in position or has been cleaned, thereby overcoming the time and energy waste caused by the use of the actual in-position signal of the upper ejector bolt in the prior art, and reducing the auxiliary mixing time while ensuring the process quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a structural diagram of an internal mixer in the prior art;

[0026] Figure 2 This is a control flow chart of the process combination of "raising the ejector bolt to its proper position + lowering the ejector bolt" in Example 1;

[0027] Figure 3 This is a control flow chart of the combined action of the "upper ejector bolt cleaning + lowering upper ejector bolt" process in Example 2;

[0028] Figure 4 It is the main monitoring screen displayed on the human-computer interaction interface;

[0029] Figure 5 This is the parameter setting screen;

[0030] Figure 6 Batch report for mixing machine;

[0031] Figure 7 Comparison of reporting time between intelligent ejector and conventional mode for mixing machines;

[0032] Figure 8 The intelligent top bolt car report is used for the mixing machine - raising the top bolt to the right position + lowering the top bolt;

[0033] Figure 9 For the mixing machine, a conventional top bolt car report is used;

[0034] Figure 10 This is a comparison chart of the effects of using the intelligent ejector pin or not on the A5 mixer;

[0035] Figure 11 This is a comparison chart of the effects of using intelligent top bolt control on B6B8 vulcanizing machines;

[0036] Figure 12 The intelligent top bolt car report is used for the mixing machine - top bolt cleaning + top bolt lowering. DETAILED DESCRIPTION

[0037] The embodiments of the present invention are described in detail below.

[0038] The present application provides a method for controlling a top bolt on an internal mixer, comprising the following steps:

[0039] Based on a preset automatic mixing process, determining whether a specific mixing combination action is currently being performed, each specific mixing combination action includes two specified mixing actions that are consecutive in sequence, and the previous mixing action is to raise the top bolt to a preset position; the specific mixing combination action indicates that the top bolt is currently being raised for turning the rubber material;

[0040] If it is detected that a specific mixing combination action is currently being executed, the upper ejector bolt position intelligent control is executed, specifically:

[0041] Control the lifting of the ejector pin, and give a simulated in-position signal during the execution of the ejector pin lifting action. After receiving the simulated in-position signal, the ejector pin stops lifting and prepares to execute the next specified mixing action in the current mixing combination action; wherein, the stop lifting position of the ejector pin is before the preset position.

[0042] The pre-set automatic mixing process includes sequentially executing mixing actions. Some of these actions are required for process control. For example, in the combination of raising the ram followed by lowering it, raising the ram is often used to turn the rubber material in the mixer, similar to kneading dough in daily life, to facilitate mixing. The ram presses against the rubber material, preventing it from turning over and mixing properly. This turning of the rubber material doesn't take long; sometimes, only a few rotations of the mixer are sufficient. In the pre-set automatic mixing process, the mixing actions of raising the ram refers to raising the ram to the pre-set upper position; clearing the ram refers to raising the ram to the pre-set clearing position. However, in automatic mixing, the ram raising and clearing actions are performed for the aforementioned "turning" purpose and do not require the ram to be actually in position or cleared.

[0043] Therefore, according to the above scheme, specific mixing action combinations are pre-set. These action combinations can indicate the purpose of raising the top pin based on process control needs such as rubber turning. In these mixing action combinations, the top pin does not need to be actually raised to the upper in-position or cleaning position according to the preset mixing action. For these mixing action combinations, by providing a simulated in-position signal to control the top pin to stop raising in advance and then lower it from the stopped position, it can save the time required to raise and lower the top pin, thereby improving efficiency while ensuring process results.

[0044] In this embodiment, the specific mixing combination action includes first raising the top bolt to a preset upper position and then lowering the top bolt; and first raising the top bolt to a preset cleaning position and then lowering the top bolt.

[0045] In the above method, during the process of lifting the ejector bolt, if the following conditions are met at the same time, a simulated in-position signal is given:

[0046] The displacement of the upper ejector bolt reaches the preset minimum value;

[0047] The pressure on the upper ram drops to zero;

[0048] The timing starts when the action of lifting the top bolt is started, and the timing reaches the preset delay time.

[0049] Through the above-mentioned pressure conditions, displacement and delay time limits, it is ensured that the upper push pin is completely separated from the rubber material before stopping the lifting, and it is ensured that the upper push pin moves up a sufficient distance without restricting the subsequent turning action of the rubber material.

[0050] Different mixing combination actions are respectively set with corresponding delay times. Before judging whether the timing reaches the preset delay time, the method includes the steps of: determining the corresponding preset delay time according to the combination of mixing actions currently being executed.

[0051] In a preferred embodiment, a manual setting module is further provided for manually setting a preset minimum value of the displacement of the upper push bolt and a preset delay time of the upper push bolt action within a preset range; the controller obtains the time parameters set by the manual setting module, and performs subsequent judgments based on the adjusted time parameters. Thus, the staff can manually adjust the above parameters according to actual conditions, so that the judgments performed based on the above parameters are more in line with actual needs. In a specific embodiment, a human-computer interaction interface is included, on which a corresponding parameter input terminal is provided corresponding to the manual setting module, and the corresponding parameter value currently set is displayed in real time. In a specific embodiment, the display of the human-computer interaction interface is as follows Figure 4 shown.

[0052] For example Figure 4As shown, the method also includes automatically recording various operating parameters during the automatic mixing process, including the ejector pin operation time, which includes the actual and simulated time for the ejector pin to be in position, and presenting these operating parameters on a user interface. The presented operating parameters can intuitively reflect the ejector pin operation time at each stage of the automatic mixing process, facilitating the operator's control of the overall working time.

[0053] Further preferably, after a batch of rubber mixing is completed, a work report is automatically generated. The work report includes the recipe time and mixing time. The recipe time refers to the time required for all mixing operations of a batch of rubber mixing to be completed, starting from the time the rubber mixing is added until the mixer discharge door closes. The mixing time refers to the time required for all mixing operations of a batch of rubber mixing to be completed, starting from the time the rubber mixing is added until the mixer discharge door opens. This allows staff to directly understand the working status of the automatic mixing process based on the work report.

[0054] The method of the present application is further described below with reference to specific examples.

[0055] like Figure 2 As shown in the control flow chart, when the automatic mixing of a truckload of materials starts production, the mixing system first performs other mixing actions, such as adding rubber, adding carbon black, adding oil, pressing the top bolt, maintaining and other mixing actions. When the mixing step is executed to "raising the top bolt to its position", the PLC control system automatically determines what the next mixing action is. If it is not the action of pressing the top bolt, the system will execute it step by step according to the setting of the mixing process formula; if the next mixing action is "lowering the top bolt", the intelligent control function of the top bolt position will be automatically triggered, and the top bolt will be placed in accordance with the mixing process formula. Figure 5 The time set by the parameters will automatically enter the simulation rising position timing. When the timing ends, it is necessary to judge whether the other two conditions are met:

[0056] 1) The displacement of the upper bolt reaches or exceeds the minimum value;

[0057] 2) The pressure on the upper push bolt is reduced to 0.

[0058] If all three conditions are met simultaneously, the PLC system automatically sends a simulated signal indicating the upper ejector bolt is in place. Upon receiving this signal, the control system automatically executes the next mixing action, lowering the upper ejector bolt. If any of these three conditions are not met, the system enters a waiting state. During this waiting period, if an actual signal indicating the upper ejector bolt is in place is received, the system automatically executes the next mixing action, lowering the upper ejector bolt. Once the upper ejector bolt is in place, the system continues with the remaining mixing actions until the current batch of material is completed and the next batch of material is mixed, repeating the cycle.

[0059] This is based on common knowledge of internal mixing processes. After raising the ram into position, other mixing actions are required, such as adding carbon black, oil, powder, and holding. If these actions are not present, then lowering the ram is necessary to allow the compound to "turn over" within the internal mixer. This generally doesn't take too long.

[0060] It should be noted that, according to the setting of the process formula, if there are 2 or more sets of "lift the top bolt into place + lower the top bolt" process combination actions in the process formula, the system will accordingly execute 2 or more times the top bolt into place intelligent signal, such as Figure 8 Vehicle report shown.

[0061] Figure 9 The vehicle report shows the same formula but with conventional top bolt function.

[0062] Example 2:

[0063] This embodiment provides an intelligent method for controlling the position of an upper ejector pin when a combined action of "upper ejector pin cleaning + lowering the upper ejector pin" is encountered. The specific method is as follows:

[0064] like Figure 3 As shown in the control flow chart, when the automatic mixing of a truckload of materials starts production, the mixing system first performs other mixing actions, such as adding rubber, adding carbon black, adding oil, pressing the top bolt, maintaining and other mixing actions. When the mixing step is executed to "cleaning the top bolt", the PLC control system automatically determines what the next mixing action is. If it is not the action of pressing the top bolt, the system will execute it step by step according to the setting of the mixing process formula; if the next mixing action is "lowering the top bolt", the intelligent control function of the top bolt position will be automatically triggered, and the top bolt will be moved according to the mixing process formula. Figure 5 The time set by the parameters will automatically enter the simulated cleaning position timing. When the timing ends, it is necessary to determine whether the other two conditions are met:

[0065] The displacement of the upper jack bolt reaches or exceeds the minimum value;

[0066] The upper ram pressure drops to 0.

[0067] If all three conditions are met simultaneously, the PLC system automatically sends a simulated signal indicating the top bolt is clear. Upon receiving this signal, the control system automatically executes the next mixing action, lowering the top bolt. If any of these three conditions are not met, the system enters a waiting state. During this waiting period, if an actual signal indicating the top bolt is clear is received, the system automatically executes the next mixing action, lowering the top bolt. Once the top bolt is lowered, the system continues with the remaining mixing actions until the current load of material is completed and the next load of material is mixed, repeating the cycle.

[0068] It should be noted that, according to the setting of the process formula, if there are 2 or more "upper bolt cleaning + lowering upper bolt" process combination actions in the process formula, the system will accordingly execute 2 or more upper bolt cleaning in place intelligent signals, such as Figure 12 Vehicle report shown.

[0069] In addition, if a hydraulic system failure occurs, the intelligent control function of the upper bolt position can be manually stopped by operating the manual setting module, such as Figure 5 As shown, a dedicated switch is provided as a manual setting module to control whether to use this function.

[0070] The beneficial effects of the present invention are described below in conjunction with the above embodiments.

[0071] like Figure 4 As shown, on the main monitoring screen of the upper auxiliary machine touch screen, you can see in real time the time it takes for the upper bolt to simulate its position / clearance, as well as the time it actually takes for the upper bolt to be in position (time value = displayed value x 0.1s). Since the upper bolt moves up and down in a reciprocating motion, every second saved during the rising process theoretically saves 2 seconds in actual production.

[0072] Figure 6 This figure compares formulation time and mixing time in the batch report for the A5 mixer. To compare the control effects of intelligent and conventional ejector bolt positions, the first 50% of a batch production schedule were controlled using the intelligent ejector bolt function, while the remaining 50% were controlled using conventional ejector bolts. The batch report clearly shows that formulation and mixing times were significantly reduced for the runs using the intelligent ejector bolt function.

[0073] Figure 7 For the sake of clarity, Figure 6 If the formula time and mixing time are listed separately for comparison, it can be seen that the formula time and mixing time of the formula with the upper push pin raised and lowered twice are shortened by an average of about 15S.

[0074] Note: The mixing time refers to the time required for all mixing operations of a batch of materials to be completed, starting from the time the rubber materials are added until the mixer discharge door is closed;

[0075] Mixing time refers to the time it takes for a batch of rubber to be added to the mixer, starting from the moment the rubber is added until the mixer's discharge door opens. After the mixer's discharge door opens, it generally needs to be held open and then closed. Therefore, for the same batch of rubber, the mixing time is longer than the mixing time.

[0076] Figure 8 and Figure 9 This is a comparison of vehicle reports using the intelligent top bolt function and the conventional top bolt function. Figure 8 It can be seen that with the intelligent top bolt function, it only takes 46-44=2s from the start of raising the top bolt to the start of lowering the top bolt; Figure 9 According to the vehicle report for a vehicle using the conventional ram position function, the time from raising the ram to lowering the ram takes 51-46 = 5 seconds. Comparing the two different ram position signal control methods, it can be seen that the intelligent ram position function can save (5-2) x 2 = 6 seconds for a set of ram position raising and lowering operations compared to not using this function. This time saving is considerable.

[0077] Figure 10 This chart compares the effects of using the intelligent ejector pin position function with and without it on the A5 mixer. Data from several randomly selected production plans was compared. The results show that using the intelligent ejector pin position function reduces the formulation time per batch by an average of 7.36 seconds and the mixing time by an average of 5.44 seconds compared to conventional operation, representing significant time savings.

[0078] Figure 11 The following chart compares the effects of using the intelligent ejector pin control function with and without it on the final mixing mills (B6 and B8). Several production plans were randomly selected for data comparison. The results show that using the intelligent ejector pin position function reduces the batching time per batch by an average of 5.85 seconds and the mixing time by an average of 6.77 seconds compared to the conventional mode, demonstrating significant time savings.

[0079] Calculations show that for all machines, every second saved in mixing time can generate approximately 1.5 million yuan in annual benefits. The average time saved per load of material for different mixing and finishing machines may vary due to differences in process formulations and mixer hydraulic systems. However, even conservatively assuming 50% of the time saved, each load of material can be saved (7.36 + 5.85) / 2 x 50% = 3.3 seconds. This translates to approximately 150 x 3.3 = 4.95 million yuan in annual benefits.

[0080] In summary, the solution of the present application can significantly shorten the internal mixing time, thereby increasing the revenue of each internal mixer.

[0081] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0082] Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention without departing from the principles and purpose of the present invention.

Claims

1. A method for controlling a top bolt on an internal mixer, characterized in that: The following steps are involved: Based on a preset automatic mixing process, determining whether a specific mixing combination action is currently being performed, each specific mixing combination action includes two specified mixing actions that are consecutive in sequence, and the previous mixing action is to raise the top bolt to a preset position; the specific mixing combination action indicates that the top bolt is currently being raised for turning the rubber material; If it is detected that a specific mixing combination action is currently being executed, the upper ejector bolt position intelligent control is executed, specifically: Control the lifting of the ejector pin, and give a simulated in-position signal during the execution of the ejector pin lifting action. After receiving the simulated in-position signal, the ejector pin stops lifting and prepares to execute the next specified mixing action in the current mixing combination action; wherein, the stop lifting position of the ejector pin is before the preset position.

2. A method for controlling a top bolt on an internal mixer according to claim 1, characterized in that: During the process of lifting the ejector bolt, if the following conditions are met at the same time, a simulated in-position signal will be given: The displacement of the upper ejector bolt reaches the preset minimum value; The pressure on the upper ram drops to zero; The timing starts when the action of lifting the top bolt is started, and the timing reaches the preset delay time.

3. A method for controlling a top bolt on an internal mixer according to claim 2, characterized in that: Different mixing combination actions are respectively set with corresponding delay times. Before determining whether the timing reaches the preset delay time, the process includes the following steps: According to the combination of the currently executing mixing actions, the corresponding preset delay time is determined.

4. A method for controlling a top bolt on an internal mixer according to claim 2 or 3, characterized in that: It also includes a manual setting module for manually setting a preset minimum value of the upper ejector bolt displacement and a preset delay time of the upper ejector bolt action within a preset range; The controller obtains the time parameters set by the manual setting module and performs subsequent judgments based on the adjusted time parameters.

5. The method for controlling the top bolt of an internal mixer according to claim 1, wherein: The determination of whether a specific refining combination action is currently being performed includes: Determine whether the currently executed or required banburying action involves the action of raising the top bolt. If so, determine whether the next action to be executed in the planned sequence is to lower the top bolt. If so, determine that a specific banburying combination action is currently being executed.

6. A method for controlling a top bolt on an internal mixer according to claim 1 or 5, characterized in that: The specific mixing combination action includes firstly raising the top bolt to a preset upper position and then lowering the top bolt; and firstly raising the top bolt to a preset cleaning position and then lowering the top bolt.

7. The method for controlling the top bolt of an internal mixer according to claim 1, characterized in that: The controller comprises a first control switch. After receiving a trigger signal from the first control switch, the controller stops using the intelligent control of the upper ejector bolt position and executes the preset automatic mixing process sequence.

8. The method for controlling the top bolt of an internal mixer according to claim 1, characterized in that: It includes automatically recording various working parameters during the automatic mixing process, the working parameters including the action time of the upper ejector bolt, the action time of the upper ejector bolt including the actual time when the upper ejector bolt is in place and the simulated time when the upper ejector bolt is in place, and presenting the working parameters on the user interaction interface.

9. A method for controlling a top bolt on an internal mixer according to claim 1 or 8, characterized in that: After the mixing of a truckload of rubber is completed, a work report is automatically generated, which includes the formulation time and mixing time. Among them, the formulation time refers to the time required for all mixing actions of this truckload to be completed from the start of the addition of rubber to the closing of the internal mixer discharge door; the mixing time refers to the time required for all mixing actions of this truckload to be completed from the start of the addition of rubber to the opening of the internal mixer discharge door.

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