Powder film pressing packaging detection control system and method

Abstract

The invention provides a powder film pressing packaging detection control system and method, and relates to the technical field of powder film pressing control systems.The powder film pressing packaging detection control system comprises a data acquisition end, a data processing end and an intelligent control end, the input end of the data acquisition end is connected with powder film pressing equipment, and the output end of the data acquisition end is connected with the data processing end; the output end of the data processing end is connected with the intelligent control end, the output end of the intelligent control end is connected with powder film pressing equipment, the data acquisition end comprises a thickness acquisition module, a density acquisition module and a defect acquisition module, the data processing end comprises a data processing module and a model processing module, and the intelligent control end comprises a feedback control module. A control strategy is set in the feedback control module; the thickness, the density and the surface defects of the powder pressed film are combined as data sources for detection and control, the related range is wide, and direct association between the detection result and the parameters of the pressed film equipment is established, so that automatic feedback adjustment is realized, a good closed-loop effect is realized, and manual intervention is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of powder film pressing control systems, and in particular to a powder film pressing packaging detection control system and method. Background Art

[0002] Pressing powder into a film (powder film pressing) and then packaging it is a process involving multiple steps and is widely used in ceramics, powder metallurgy, electronic materials, energy materials and other fields. The powder needs to be evenly mixed with auxiliary materials such as binders and lubricants to improve the pressing performance. The powder particles are then compacted through external pressure or other forming methods to generate physical or chemical bonding between the particles, forming a dense film structure, and then subsequent packaging operations are carried out.

[0003] Currently, the continuous production of large-area thin films typically uses a roll-to-roll lamination method. This involves mixing powder with a solvent to create a slurry, which is then passed through a casting machine to form an initial film. Lamination is then used to increase density and strength. This process requires monitoring and control.

[0004] Powder film packaging detection and control is a key link to ensure film quality, improve production efficiency, and reduce scrap rate, especially when film materials are widely used in high-requirement fields such as electronics, energy, ceramics, and food. The necessity of detection and control is particularly prominent. However, in the existing technology, powder film detection usually uses a contact thickness meter to detect the thickness of the film, which has limited accuracy. At the same time, the detection results cannot be quickly transmitted to the film pressing equipment for parameter adjustment, such as pressure, speed, roller gap, etc., resulting in the problem cannot be corrected in the first time, and the detection data source is single, which cannot fully reflect the quality problem of the material pressing, thereby failing to form a benign closed loop, so that the parameters still need to be manually intervened and adjusted. Therefore, the present invention proposes a powder film packaging detection control system and method to solve the problems existing in the existing technology. Summary of the Invention

[0005] In response to the above problems, the purpose of the present invention is to propose a powder film packaging detection control system and method. This powder film packaging detection control system and method combines multiple data sources to provide support for powder film quality detection, and establishes a direct correlation between the detection results and the film pressing equipment parameters, realizing automatic feedback adjustment, and can solve the problems existing in the prior art.

[0006] To achieve the purpose of the present invention, the present invention is implemented through the following technical solutions: a powder film packaging detection and control system, including a data acquisition end for collecting data in the powder film process, a data processing end for processing and calculating the collected data, and an intelligent control end for performing feedback control according to the processed data, the input end of the data acquisition end is connected to the powder film equipment, and the output end of the data acquisition end is connected to the data processing end, the output end of the data processing end is connected to the intelligent control end, the output end of the intelligent control end is connected to the powder film equipment, the data acquisition end includes a thickness acquisition module, a density acquisition module and a defect acquisition module, the data processing end includes a data processing module and a model processing module, the intelligent control end includes a feedback control module, and a control strategy is provided in the feedback control module.

[0007] A further improvement is that the data acquisition end further includes an equipment parameter acquisition module for acquiring working parameters of the lamination equipment, and the output end of the equipment parameter acquisition module is connected to the input end of the feedback control module.

[0008] A further improvement is that the system further includes a data storage end for storing data, and the data storage end includes a data server and a visualization module.

[0009] A further improvement is that the system further includes a monitoring data terminal for monitoring the production status, the monitoring data terminal includes a video monitoring module and an alarm module, and the input end of the alarm module is connected to the output end of the feedback control module.

[0010] A further improvement is that: the data processing end also includes a temporary storage module, and the input end and output end of the temporary storage module are connected to the data processing module and the model processing module respectively.

[0011] A further improvement is that the feedback control module includes a data input unit, a control strategy unit, an execution instruction output unit and a feedback monitoring unit, and the control strategy unit stores the control strategy.

[0012] A further improvement is that the control strategy corresponding to the thickness acquisition module is: Set the thickness target value T 目标 , the thickness T collected by the thickness collection module 采集 and thickness target value T 目标 Compare and adjust working parameters according to the comparison results.

[0013] A further improvement is that the control strategy corresponding to the density acquisition module is: Setting density targets , the density collected by the density acquisition module and density target value Compare and adjust working parameters according to the comparison results.

[0014] A further improvement is that the model processing module is used to collect data according to the defect collection module and output defect categories, and the defect categories include cracks, pores and depressions.

[0015] A control method for a powder film packaging detection and control system, comprising the following steps: Step 1: Parameter setting Set the initial parameters of the powder film lamination equipment according to the specifications of the powder film lamination product, including pressure, film thickness and roller gap; Step 2: Obtaining and processing parameters The corresponding data is collected by the thickness acquisition module, density acquisition module and defect acquisition module, and is processed by the data processing module and the model processing module respectively, and then enters the feedback control module; Step 3: Parameter adjustment The feedback control module adjusts the working parameters of the powder film pressing equipment based on the initial parameters according to the preset control strategy.

[0016] The beneficial effects of the present invention are: the powder film packaging detection and control system provided by the present invention combines the thickness, density and surface defects of the powder film as the data source of detection and control, covers a wide range, and analyzes the powder film quality results more accurately, and then uses the feedback control module and control strategy to establish a direct relationship between the detection results and the film equipment parameters, thereby realizing automatic feedback adjustment, and automatically adjusting the film pressure, roller gap, transmission speed, etc. according to the real-time detection results, achieving a good closed-loop effect, reducing manual intervention, and improving the quality and efficiency of powder film products. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the system structure provided by the present invention. DETAILED DESCRIPTION

[0018] In order to deepen the understanding of the present invention, the present invention will be further described in detail below with reference to the examples. The examples are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0019] Powder lamination is a process that forms a film from powdered material under pressure. This process is commonly used in various industrial fields, such as ceramics, powder metallurgy, and electronic component manufacturing. During the lamination process, the powder is first uniformly mixed with the necessary binders or other additives to improve the strength and forming effect of the film after lamination.

[0020] Thin films are typically formed continuously. Powder lamination equipment utilizes rotating rollers to continuously press powder into film-like products, making it suitable for large-area film production. This process can lead to uneven roller pressure and gaps between the rollers, resulting in uneven thickness and density of the finished powder film, as well as surface defects. This necessitates testing. However, while existing technologies involve testing, the results are fed back to a monitoring computer, requiring operator intervention to adjust parameters, resulting in a slow overall response time.

[0021] Therefore, the present invention is based on Figure 1 As shown, and based on the following embodiments, a control system and method for detecting and controlling powder film packaging is provided. In the following embodiments, errors in the calculation and comparison of values ​​are negligible. Furthermore, the following embodiments involve a convolutional neural network, which identifies surface defects such as cracks, pores, and depressions.

[0022] Example 1 This embodiment provides a powder film packaging detection and control system, including a data acquisition terminal for collecting data during the powder film pressing process. The data acquisition terminal includes: Thickness acquisition module: It is used to monitor the thickness of powder film products in real time to ensure that product quality meets standards and provide basic data support for parameter optimization in the production process. In this embodiment, it adopts a laser thickness measurement method to measure the thickness by laser reflection, which is a contactless measurement. The collected analog signal is converted into a digital signal by the data processing module, and noise filtering and data smoothing are performed to obtain the thickness T of the powder film product. 采集 , and the control strategy corresponding to the thickness acquisition module is: Set the thickness target value T 目标 , the thickness T collected by the thickness collection module 采集 and thickness target value T 目标 Compare and adjust the operating parameters based on the comparison results. For example, if the collected thickness is greater than or less than the target value, you can adjust the lamination speed, material feed, and lamination pressure parameters until the collected thickness reaches the target value. Therefore, the following adjustment method involves three lamination equipment operating parameters: lamination speed, material feed, and lamination pressure.

[0023] Density acquisition module: It is used to measure the density of powder film products to ensure the compactness and uniformity of the products and provide basic data support for parameter optimization in the production process. In this embodiment, a laser density measurement method is adopted. Its principle is to measure the density through the penetration ability of the laser and the absorption and scattering characteristics of the material to the laser (related to the density). The intensity change when the laser penetrates the film can reflect the density distribution of the film. The calculation formula is as follows:

[0024] in, is the transmitted light intensity, is the incident light intensity, is the absorption coefficient of the material (obtained through experimental testing in advance), is the film thickness T.

[0025] The control strategy corresponding to the density acquisition module is: Setting density targets , the density collected by the density acquisition module and density target value Compare and adjust the operating parameters based on the comparison results. In this embodiment, density and thickness are both directly calculated values. Therefore, in the feedback control module, the SVM (Support Vector Machine) algorithm is used. It is a powerful classification algorithm that can quickly determine whether the thickness value or density value is abnormal based on a predefined threshold range (or classification model).

[0026] Defect acquisition module: used to collect surface image data of powder film products. Specifically, an industrial camera is used to continuously obtain image data of the surface of powder film products and input it into the data processing module. Then, grayscale processing, denoising and enhancement processing are performed. Then, a model processing module is used, which has a built-in trained convolutional neural network to identify and extract the features of the defects. According to the extracted features, classification is performed. Then, another step of calculation is performed to calculate the parameters corresponding to each defect, including the coordinate position of the defect and the area occupied by the defect, and the severity of the defect is evaluated, which is divided into mild, medium and severe. The mild degree is adjustable, and the medium and severe degrees are alarm levels. Furthermore, in this embodiment, the classification is divided into three categories, namely cracks, pores and depressions. Then the control strategy corresponding to the defect acquisition module is: Set the threshold conditions for defect triggering respectively, for example: (1) When the crack length or number is greater than the crack length or number threshold, the working parameters are dynamically adjusted; (2) When the pore diameter or density is greater than the pore diameter or density threshold, the working parameters are dynamically adjusted; (3) When the depression depth is greater than the depression depth threshold, the working parameters are dynamically adjusted. The above adjustment of the working parameters is consistent with that of the density acquisition module, and is adjusted accordingly through three parameters.

[0027] The data processing end is used to process and calculate the collected data. The data processing end includes the data processing module: Responsible for receiving, organizing, and processing raw data from the data acquisition end, that is, pre-processing it, including noise filtering and data smoothing, to ensure data accuracy. The processed data is then stored in the temporary storage module.

[0028] Temporary storage module: The input and output ends of the temporary storage module are connected to the data processing module and the model processing module respectively. Its main purpose is to temporarily store processed data and provide basic data for subsequent calculations or model processing.

[0029] Model processing module: It is equipped with a trained convolutional neural network for processing surface defects. Accordingly, in this embodiment, the thickness and density are directly calculated values, so they do not need to pass through the convolutional neural network and directly enter the feedback control module.

[0030] An intelligent control terminal for performing feedback control based on processed data includes a feedback control module, and a control strategy is provided in the feedback control module. Specifically, the feedback control module includes a data input unit for data input, a control strategy unit for managing the control strategy, an execution instruction output unit for executing the control strategy and program, and a feedback monitoring unit for feeding back the execution results. The control strategy unit stores the control strategy. Accordingly, the feedback control module corresponds to a PLC controller, which performs corresponding operations according to the programmed program.

[0031] The data acquisition end also includes an equipment parameter acquisition module for obtaining the working parameters of the film pressing equipment. The output end of the equipment parameter acquisition module is connected to the input end of the feedback control module. Its function is to obtain the working parameters of the film pressing equipment. Subsequent adjustments are based on the obtained working parameters.

[0032] The system also includes a data storage end for storing data. The data storage end includes a data server and a visualization module. The data server is used to store data, including detection data, adjustment data, etc., for subsequent tracing, while visualization is to intuitively display the collected and stored data in the form of charts, images, reports, etc.

[0033] The system also includes a monitoring data terminal for monitoring the production status. The monitoring data terminal includes a video monitoring module and an alarm module. The video monitoring module is used to monitor the production process in real time and record the production status (including the operating status of the laminating equipment, the material supply status, the personnel operation, etc.). The input end of the alarm module is connected to the output end of the feedback control module. The alarm module uses an audible and visual alarm. For example, during the detection process, if the thickness is found to be different for more than three consecutive times, the system needs to intervene and adjust, and a corresponding alarm will be issued. That is, the conditions for triggering the alarm can be configured according to the user.

[0034] The input end of the data acquisition end is connected to the powder film pressing equipment, the output end of the data acquisition end is connected to the data processing end, the output end of the data processing end is connected to the intelligent control end, and the output end of the intelligent control end is connected to the powder film pressing equipment to form a closed-loop control, and the parameters of the powder film pressing process are adjusted in real time according to the detection data.

[0035] Example 2 This embodiment provides a control method for a powder film packaging detection and control system, comprising the following steps: Step 1: Parameter setting Set the initial parameters of the powder film lamination equipment according to the specifications of the powder film lamination product, including pressure, film thickness and roller gap; Step 2: Obtaining and processing parameters The corresponding data is collected by the thickness acquisition module, density acquisition module and defect acquisition module, and is processed by the data processing module and the model processing module respectively, and then enters the feedback control module; Step 3: Parameter adjustment The feedback control module adjusts the working parameters of the powder film pressing equipment based on the initial parameters according to the preset control strategy.

[0036] The above method is based on Example 1, and is controlled to obtain a finished powder film, which is then compression molded (using a stamping die to punch the film into a specific shape) to process it into a specific shape (such as sheet and block) for subsequent packaging, transportation and use.

[0037] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above-described embodiments. The above-described embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and improvements may be made to the present invention without departing from the framework and scope of application of the present invention. Such changes and improvements are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A powder film packaging detection and control system, characterized by: It includes a data acquisition end for collecting data during the powder film pressing process, a data processing end for processing and calculating the collected data, and an intelligent control end for performing feedback control based on the processed data. The input end of the data acquisition end is connected to the powder film pressing equipment, and the output end of the data acquisition end is connected to the data processing end. The output end of the data processing end is connected to the intelligent control end. The output end of the intelligent control end is connected to the powder film pressing equipment. The data acquisition end includes a thickness acquisition module, a density acquisition module and a defect acquisition module. The data processing end includes a data processing module and a model processing module. The intelligent control end includes a feedback control module. A control strategy is provided in the feedback control module.

2. A powder film packaging detection and control system according to claim 1, characterized in that: The data acquisition end further includes an equipment parameter acquisition module for acquiring working parameters of the lamination equipment, and the output end of the equipment parameter acquisition module is connected to the input end of the feedback control module.

3. The powder film packaging detection and control system according to claim 1, characterized in that: The system further comprises a data storage end for storing data, wherein the data storage end comprises a data server and a visualization module.

4. A powder film packaging detection and control system according to claim 1, characterized in that: The system further comprises a monitoring data terminal for monitoring the production status, wherein the monitoring data terminal comprises a video monitoring module and an alarm module, and an input terminal of the alarm module is connected to an output terminal of the feedback control module.

5. The powder film packaging detection and control system according to claim 1, characterized in that: The data processing end also includes a temporary storage module, and the input end and output end of the temporary storage module are connected to the data processing module and the model processing module respectively.

6. The powder film packaging detection and control system according to claim 1, characterized in that: The feedback control module includes a data input unit, a control strategy unit, an execution instruction output unit and a feedback monitoring unit, and the control strategy unit stores a control strategy.

7. The powder film packaging detection and control system according to claim 1, characterized in that: The control strategy corresponding to the thickness acquisition module is: Set the thickness target value T 目标 , the thickness T collected by the thickness collection module 采集 and thickness target value T 目标 Compare and adjust working parameters according to the comparison results.

8. The powder film packaging detection and control system according to claim 1, characterized in that: The control strategy corresponding to the density acquisition module is: Setting density targets , the density collected by the density acquisition module and density target value Compare and adjust working parameters according to the comparison results.

9. The powder film packaging detection and control system according to claim 1, characterized in that: The model processing module is used to collect data according to the defect collection module and output defect categories, which include cracks, pores and depressions.

10. A control method for a powder film packaging detection and control system according to claim 1, characterized in that: The following steps are involved: Step 1: Parameter setting Set the initial parameters of the powder film lamination equipment according to the specifications of the powder film lamination product, including pressure, film thickness and roller gap; Step 2: Obtaining and processing parameters The corresponding data is collected by the thickness acquisition module, density acquisition module and defect acquisition module, and is processed by the data processing module and the model processing module respectively, and then enters the feedback control module; Step 3: Parameter adjustment The feedback control module adjusts the working parameters of the powder film pressing equipment based on the initial parameters according to the preset control strategy.

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