Full-automatic essential balm filling control system based on PLC online monitoring

Abstract

The invention relates to the technical field of filling automation control, in particular to a full-automatic essential balm filling control system based on PLC online monitoring, which comprises a filling parameter real-time acquisition module, a dynamic coupling analysis module, a multi-axis cooperative execution module, a foreign matter real-time detection module, an interlocking control module and a filling quality feedback module. Wherein the filling parameter real-time acquisition module is used for acquiring temperature data of a filling head, a liquid viscosity value and the flow velocity of a filling pipeline in real time; and the dynamic coupling analysis module is used for establishing a correlation model of the temperature gradient and the viscosity change rate and generating a dynamic compensation parameter set. According to the method, the nonlinear correlation model of the temperature and the viscosity change rate is constructed, and the dynamic compensation parameter set is generated, so that self-adaptive precise control in the filling process and automatic response linkage of abnormal working conditions are realized, and the stability and the intelligent level of a filling system are remarkably improved.

Description

Technical Field

[0001] The present invention relates to the technical field of filling automation control, and in particular to a full-automatic wind oil essence filling control system based on PLC online monitoring. Background Art

[0002] In the industrial filling process of highly volatile liquids such as Fengyoujing, the filling accuracy and stability are affected by many factors, among which fluctuations in liquid viscosity, changes in ambient temperature and unstable pipeline flow rate are key factors leading to fluctuations in filling quality; traditional filling control systems mostly adopt fixed parameter modes and cannot be dynamically adjusted according to real-time working conditions, resulting in large deviations in filling volume and uncontrollable filling speed; in addition, high-precision filling tasks also face problems such as difficulty in detecting foreign matter mixing, delayed response to filling abnormalities and insufficient coordinated control of execution units, which affect the yield and filling efficiency.

[0003] Existing technologies suffer from technical bottlenecks such as poor decoupling modeling capabilities between filling parameters and environmental factors, delayed response adjustments, and non-adaptive compensation mechanisms. These bottlenecks make it difficult to meet the high-precision requirements of Fengyoujing filling, which require precise filling and stopping, and minimal perturbation response. Furthermore, foreign object detection often relies on manual spot checks and lacks interlocking control and abnormality linkage mechanisms, making it impossible to promptly handle abnormal operating conditions while ensuring safety. Therefore, a fully automated Fengyoujing filling control system based on PLC online monitoring is urgently needed to address these issues. Summary of the Invention

[0004] Based on the above objectives, the present invention provides a fully automatic wind oil essence filling control system based on PLC online monitoring, which solves the problem that traditional fixed parameter control is difficult to maintain accuracy in multi-variable fluctuation scenarios.

[0005] The fully automatic wind oil essence filling control system based on PLC online monitoring includes a filling parameter real-time acquisition module, a dynamic coupling analysis module, a multi-axis collaborative execution module, a foreign body real-time detection module, an interlocking control module, and a filling quality feedback module; among which: Filling parameter real-time acquisition module: used to collect the temperature data of the filling head, liquid viscosity value and filling pipeline flow rate in real time; Dynamic coupling analysis module: used to receive temperature data, viscosity value and flow rate, establish the correlation model between temperature gradient and viscosity change rate, and generate dynamic compensation parameter set; Multi-axis collaborative execution module: used to synchronously control the speed of the filling motor, the opening of the filling valve and the pipeline pressure according to the dynamic compensation parameter set; Foreign body real-time detection module: used to obtain real-time images of the inner cavity of the filling bottle, extract foreign body features and generate abnormal trigger signals; Interlock control module: used to execute interlock actions such as power off of filling valve, activation of standby station and removal of abnormal bottles after abnormal trigger signal; Filling quality feedback module: used to obtain the deviation data between the actual filling volume and the preset value, and feed the deviation data back to the dynamic coupling analysis module to reconstruct the correlation model.

[0006] Optionally, the filling parameter real-time acquisition module includes a temperature sensing unit, a viscosity detection unit, a flow rate measurement unit, and a data synchronization unit; wherein: Temperature sensing unit: used to collect the surface temperature of the filling head through a non-contact infrared sensor, with a sampling frequency of ≥10Hz; Viscosity detection unit: used to measure the viscosity of liquid in real time using a rotary viscometer and transmit data through the RS485 interface; Flow rate measurement unit: used to monitor the flow rate of the filling pipeline through a wall flow meter with an accuracy of ±0.5% FS; Data synchronization unit: used to upload three types of data to the PLC in real time and refresh them synchronously with a period of 100ms.

[0007] Optionally, the dynamic coupling analysis module includes a temperature-viscosity modeling unit, a compensation generation unit, and a data feedback interface unit; wherein: Temperature-viscosity modeling unit: used to construct a correlation model of the nonlinear function between filling temperature and liquid viscosity change rate; Compensation generation unit: used to generate a dynamic compensation parameter set according to the modeling results, wherein the dynamic compensation parameter set includes a target filling speed correction value, a valve adjustment coefficient, and a pressure threshold adjustment factor; Data feedback interface unit: used to receive deviation data from the filling quality feedback module, update the associated model parameters and perform closed-loop correction.

[0008] Model verification and optimization subunit: After obtaining the fitting function, it is used to verify the model through multiple sets of test data under actual working conditions, and repeatedly correct the deviation between the model prediction results and the actual measurement values ​​until the error is stabilized within the allowable range.

[0009]

[0010] Synchronous coordination unit: used to align the actions performed by the motor drive unit, valve control unit and pressure regulation unit in real time in the PLC master control program, ensuring that the timing accuracy of the three-axis coordinated operation is less than 50ms.

[0011] Optionally, the foreign body real-time detection module includes an optical imaging unit, a feature extraction unit, a feature recognition unit, and a signal generation unit; wherein: Optical imaging unit: equipped with a 450nm blue LED light source and a high-speed linear array camera, capturing images of the bottom of the bottle cavity at a 60° angle; Feature extraction unit: used to identify foreign body features with a contour area greater than 0.1mm² in the image using the Canny edge detection algorithm; Signal generation unit: When a foreign object is detected in the same coordinate area in three consecutive frames of images, an abnormal trigger signal with position coding is output.

[0012] Optionally, the interlock control module includes a power failure response unit, a backup activation unit, and a removal control unit; wherein: Power-off response unit: used to perform emergency power-off operation on the filling valve within 20ms after receiving an abnormal trigger signal; Standby activation unit: used to activate and switch to the standby filling station to ensure the overall filling rhythm is not interrupted; Remove the control unit: used to control the bottle conveying mechanism to divert bottles marked as abnormal to the abnormal recycling channel.

[0013] Optionally, the filling quality feedback module includes a weighing sensor unit, a data comparison unit, and a closed-loop feedback unit; wherein: Weighing sensor unit: used to install a strain gauge weighing sensor with a resolution of 0.01g at the filling completion station to obtain the actual filling volume; Data comparison unit: used to perform difference calculation between the actual filling volume and the preset standard value to generate deviation data with positive and negative signs; Closed-loop feedback unit: When the deviation data continuously exceeds the set threshold, the deviation data is input into the dynamic coupling analysis module, and the weight coefficient of the association model is optimized through the particle swarm algorithm.

[0014] Beneficial effects of the present invention: The present invention, by introducing a real-time filling parameter acquisition module and a temperature-viscosity modeling and analysis mechanism, realizes three-dimensional coupled modeling of temperature, viscosity and flow rate during the filling process, can dynamically generate a compensation parameter set and adjust the filling speed, valve opening and pressure threshold in real time, thereby significantly improving the system's adaptability to environmental disturbances; the compensation curve established by nonlinear modeling and polynomial fitting methods can accurately reflect the rheological characteristics of the filling medium, realize closed-loop adjustment of the filling state, and solve the problem that traditional fixed parameter control is difficult to maintain accuracy in multi-variable fluctuation scenarios.

[0015] The present invention establishes a foreign body detection module by combining image recognition technology and links it with the interlocking control module to realize automatic identification of foreign objects in bottles before filling, emergency interruption of the filling action, and automatic rejection of abnormal bottles, effectively improving the degree of automation of product quality control; the system uses the filling quality feedback module to perform real-time closed-loop correction of deviations, so that the modeling mechanism has the ability of continuous learning and parameter updating. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only for the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0017] Figure 1 A schematic diagram of a filling control system according to an embodiment of the present invention; Figure 2 Schematic diagram of a dynamic coupling analysis module according to an embodiment of the present invention. DETAILED DESCRIPTION

[0018] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments. It is also noted that, to provide a more detailed description, the following embodiments are best and preferred embodiments, and those skilled in the art may employ alternative methods for implementing certain known technologies. Furthermore, the accompanying drawings are intended only to provide a more detailed description of the embodiments and are not intended to limit the present invention.

[0019] It should be noted that references in the specification to "one embodiment," "an embodiment," "exemplary embodiments," "some embodiments," etc. indicate that the described embodiments may include specific features, structures, or characteristics, but not necessarily every embodiment will include such specific features, structures, or characteristics. Furthermore, when specific features, structures, or characteristics are described in conjunction with an embodiment, it is within the knowledge of persons skilled in the relevant art to implement such features, structures, or characteristics in conjunction with other embodiments (whether or not explicitly described).

[0020] In general, terms can be understood, at least in part, from their use in context. For example, depending at least in part on the context, the term "one or more" as used herein can be used to describe any feature, structure, or characteristic in the singular sense, or can be used to describe a combination of features, structures, or characteristics in the plural sense. Additionally, the term "based on" can be understood as not necessarily intended to convey an exclusive set of factors, but can instead, depending at least in part on the context, allow for the presence of other factors that are not necessarily explicitly described.

[0021] like Figure 1-Figure 2As shown in the figure, the fully automatic wind oil essence filling control system based on PLC online monitoring includes a filling parameter real-time acquisition module, a dynamic coupling analysis module, a multi-axis collaborative execution module, a foreign body real-time detection module, an interlocking control module, and a filling quality feedback module; among which: Filling parameter real-time acquisition module: used to collect the temperature data of the filling head, liquid viscosity value and filling pipeline flow rate in real time; Dynamic coupling analysis module: used to receive temperature data, viscosity value and flow rate, establish the correlation model between temperature gradient and viscosity change rate, and generate dynamic compensation parameter set; Multi-axis collaborative execution module: used to synchronously control the speed of the filling motor, the opening of the filling valve and the pipeline pressure according to the dynamic compensation parameter set; Foreign body real-time detection module: used to obtain real-time images of the inner cavity of the filling bottle, extract foreign body features and generate abnormal trigger signals; Interlock control module: used to execute interlock actions such as power off of filling valve, activation of standby station and removal of abnormal bottles after abnormal trigger signal; Filling quality feedback module: used to obtain the deviation data between the actual filling volume and the preset value, and feed the deviation data back to the dynamic coupling analysis module to reconstruct the correlation model.

[0022] The filling parameter real-time acquisition module includes a temperature sensing unit, a viscosity detection unit, a flow rate measurement unit, and a data synchronization unit; wherein: Temperature sensing unit: used to collect the surface temperature of the filling head through a non-contact infrared sensor (model MLX90614), with a sampling frequency of ≥10Hz; Viscosity detection unit: used to measure the viscosity of liquid in real time using a rotary viscometer (model NDJ-8S) and transmit data via the RS485 interface; Flow rate measurement unit: used to monitor the flow rate of the filling pipeline through the wall flow meter (model IFM4080), with an accuracy of ±0.5% FS; Data synchronization unit: used to upload three types of data to the PLC in real time and refresh them synchronously with a period of 100ms.

[0023] The dynamic coupling analysis module includes a temperature-viscosity modeling unit, a compensation generation unit, and a data feedback interface unit; among which: Temperature-viscosity modeling unit: used to construct a correlation model of the nonlinear function between filling temperature and liquid viscosity change rate; Compensation generation unit: used to generate a dynamic compensation parameter set based on the modeling results. The dynamic compensation parameter set includes a target filling speed correction value, a valve adjustment coefficient, and a pressure threshold adjustment factor. Data feedback interface unit: used to receive deviation data from the filling quality feedback module, update the associated model parameters and perform closed-loop correction.

[0024] Model verification and optimization subunit: After obtaining the fitting function, it is used to verify the model through multiple sets of test data under actual working conditions, and repeatedly correct the deviation between the model prediction results and the actual measurement values ​​until the error is stabilized within the allowable range.

[0025]

[0026]

[0027] Synchronous coordination unit: used to align the actions performed by the motor drive unit, valve control unit and pressure regulation unit in real time in the PLC master control program, ensuring that the timing accuracy of the three-axis coordinated operation is less than 50ms.

[0028] The foreign body real-time detection module includes an optical imaging unit, a feature extraction unit, a feature recognition unit, and a signal generation unit; wherein: Optical imaging unit: equipped with a 450nm blue LED light source and a high-speed linear array camera, capturing images of the bottom of the bottle cavity at a 60° angle; Feature extraction unit: used to identify foreign body features with a contour area greater than 0.1mm² in the image using the Canny edge detection algorithm; Signal generation unit: When a foreign object is detected in the same coordinate area in three consecutive frames of images, an abnormal trigger signal with position coding is output.

[0029] The interlock control module includes a power failure response unit, a backup enabling unit, and a removal control unit; wherein: Power-off response unit: used to perform emergency power-off operation on the filling valve within 20ms after receiving an abnormal trigger signal; Standby activation unit: used to activate and switch to the standby filling station to ensure the overall filling rhythm is not interrupted; Remove the control unit: used to control the bottle conveying mechanism to divert bottles marked as abnormal to the abnormal recycling channel.

[0030] The filling quality feedback module includes a weighing sensor unit, a data comparison unit, and a closed-loop feedback unit; wherein: Weighing sensor unit: used to install a strain gauge weighing sensor with a resolution of 0.01g at the filling completion station to obtain the actual filling volume; Data comparison unit: used to perform difference calculation between the actual filling volume and the preset standard value to generate deviation data with positive and negative signs; Closed-loop feedback unit: When the deviation data continuously exceeds the set threshold, the deviation data is input into the dynamic coupling analysis module, and the weight coefficient of the association model is optimized through the particle swarm algorithm.

[0031] The present invention encompasses any alternatives, modifications, equivalents, and solutions that fall within the spirit and scope of the present invention. To provide a thorough understanding of the present invention, specific details are described in detail below in connection with the preferred embodiments of the present invention, but those skilled in the art will be able to fully understand the present invention without these detailed descriptions. Furthermore, to avoid unnecessary confusion regarding the essence of the present invention, well-known methods, processes, procedures, components, and circuits have not been described in detail.

[0032] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. The fully automatic wind oil essence filling control system based on PLC online monitoring is characterized by: It includes a filling parameter real-time acquisition module, a dynamic coupling analysis module, a multi-axis collaborative execution module, a foreign body real-time detection module, an interlocking control module, and a filling quality feedback module; among which: Filling parameter real-time acquisition module: used to collect the temperature data of the filling head, liquid viscosity value and filling pipeline flow rate in real time; Dynamic coupling analysis module: used to receive temperature data, viscosity value and flow rate, establish the correlation model between temperature gradient and viscosity change rate, and generate dynamic compensation parameter set; Multi-axis collaborative execution module: used to synchronously control the speed of the filling motor, the opening of the filling valve and the pipeline pressure according to the dynamic compensation parameter set; Foreign body real-time detection module: used to obtain real-time images of the inner cavity of the filling bottle, extract foreign body features and generate abnormal trigger signals; Interlock control module: used to execute interlock actions such as power off of filling valve, activation of standby station and removal of abnormal bottles after abnormal trigger signal; Filling quality feedback module: used to obtain the deviation data between the actual filling volume and the preset value, and feed the deviation data back to the dynamic coupling analysis module to reconstruct the correlation model.

2. The fully automatic wind oil essence filling control system based on PLC online monitoring according to claim 1 is characterized in that: The filling parameter real-time acquisition module includes a temperature sensing unit, a viscosity detection unit, a flow rate measurement unit and a data synchronization unit; wherein: Temperature sensing unit: used to collect the surface temperature of the filling head through a non-contact infrared sensor, with a sampling frequency of ≥10Hz; Viscosity detection unit: used to measure the viscosity of liquid in real time using a rotary viscometer and transmit data through the RS485 interface; Flow rate measurement unit: used to monitor the flow rate of the filling pipeline through a wall flow meter with an accuracy of ±0.5% FS; Data synchronization unit: used to upload three types of data to the PLC in real time and refresh them synchronously with a period of 100ms.

3. The fully automatic wind oil essence filling control system based on PLC online monitoring according to claim 1 is characterized in that: The dynamic coupling analysis module includes a temperature-viscosity modeling unit, a compensation generation unit, and a data feedback interface unit; wherein: Temperature-viscosity modeling unit: used to construct a correlation model of the nonlinear function between filling temperature and liquid viscosity change rate; Compensation generation unit: used to generate a dynamic compensation parameter set according to the modeling results, wherein the dynamic compensation parameter set includes a target filling speed correction value, a valve adjustment coefficient, and a pressure threshold adjustment factor; Data feedback interface unit: used to receive deviation data from the filling quality feedback module, update the associated model parameters and perform closed-loop correction.

4. The fully automatic wind oil essence filling control system based on PLC online monitoring according to claim 3 is characterized in that: The temperature-viscosity modeling unit includes: Model verification and optimization subunit: After obtaining the fitting function, it is used to verify the model through multiple sets of test data under actual working conditions, and repeatedly correct the deviation between the model prediction results and the actual measurement values ​​until the error stabilizes within the allowable range.

5. The fully automatic wind oil essence filling control system based on PLC online monitoring according to claim 3 is characterized in that: The compensation generating unit includes: Generates a complete set of motion compensation parameters.

6. The fully automatic wind oil essence filling control system based on PLC online monitoring according to claim 1 is characterized in that: The multi-axis collaborative execution module includes a motor drive unit, a valve control unit, a pressure regulation unit and a synchronization coordination unit; wherein: Synchronous coordination unit: used to align the actions performed by the motor drive unit, valve control unit and pressure regulation unit in real time in the PLC master control program, ensuring that the timing accuracy of the three-axis coordinated operation is less than 50ms.

7. The fully automatic wind oil essence filling control system based on PLC online monitoring according to claim 1 is characterized in that: The foreign body real-time detection module includes an optical imaging unit, a feature extraction unit, a feature recognition unit and a signal generation unit; wherein: Optical imaging unit: equipped with a 450nm blue LED light source and a high-speed linear array camera, capturing images of the bottom of the bottle cavity at a 60° angle; Feature extraction unit: used to identify foreign body features with a contour area greater than 0.1mm² in the image using the Canny edge detection algorithm; Signal generation unit: When a foreign object is detected in the same coordinate area in three consecutive frames of images, an abnormal trigger signal with position coding is output.

8. The fully automatic wind oil essence filling control system based on PLC online monitoring according to claim 1 is characterized in that: The interlock control module includes a power failure response unit, a backup enabling unit, and a removal control unit; wherein: Power-off response unit: used to perform emergency power-off operation on the filling valve within 20ms after receiving an abnormal trigger signal; Standby activation unit: used to activate and switch to the standby filling station to ensure the overall filling rhythm is not interrupted; Remove the control unit: used to control the bottle conveying mechanism to divert bottles marked as abnormal to the abnormal recycling channel.

9. The fully automatic wind oil essence filling control system based on PLC online monitoring according to claim 1 is characterized in that: The filling quality feedback module includes a weighing sensor unit, a data comparison unit and a closed-loop feedback unit; wherein: Weighing sensor unit: used to install a strain gauge weighing sensor with a resolution of 0.01g at the filling completion station to obtain the actual filling volume; Data comparison unit: used to perform difference calculation between the actual filling volume and the preset standard value to generate deviation data with positive and negative signs; Closed-loop feedback unit: When the deviation data continuously exceeds the set threshold, the deviation data is input into the dynamic coupling analysis module, and the weight coefficient of the association model is optimized through the particle swarm algorithm.

Images