Method for dynamically adjusting white ink coating liquid amount based on real-time sensing feedback and related device

Abstract

The application discloses a white ink coating liquid quantity dynamic adjustment method based on real-time sensing feedback and a related device, and the method comprises the following steps: before a white ink coating station, surface characteristic data of a substrate to be coated is acquired in real time through a multispectral sensor; after the white ink coating station completes white ink coating, optical characteristic data of a white ink coating layer is collected in real time through a high-precision spectral imager or a colorimeter; the surface characteristic data and the optical characteristic data are optimized with preset target whiteness, hiding power and drying speed as optimization targets, and a deviation of a current white ink coating quantity from a target value and a coating ink quantity adjustment parameter based on historical adjustment data and a prediction trend are dynamically output; and the deviation of the current white ink coating quantity from the target value and the coating ink quantity adjustment parameter based on the historical adjustment data and the prediction trend are used to adjust white ink coating mechanism parameters in real time through a PID controller. The application realizes more stable and more adaptive white ink coating quality control, improves product consistency and reduces the waste product rate.

Description

Technical Field

[0001] This invention relates to the field of printing and coating technology, specifically to a method and apparatus for dynamic adjustment of white ink coating volume based on real-time sensor feedback, and a computing device. Background Technology

[0002] In industries such as printing, packaging, and display panel manufacturing, white ink coating is widely used to provide opacity, increase whiteness, improve visual effects, or serve as a base for subsequent color printing. Traditional white ink coating technologies, including inkjet printing, roller coating, and blade coating, often rely on preset parameters, experience-based adjustments, or offline sampling. During the coating process, fluctuations in substrate characteristics (such as surface energy and roughness), environmental conditions (such as temperature and humidity), or ink characteristics cannot be detected and adjusted in real time. This lag or lack of dynamic adjustment capability leads to large fluctuations in coating quality, easily resulting in uneven whiteness, insufficient opacity, and poor drying, ultimately causing high product scrap rates and low production efficiency. Furthermore, different batches, different suppliers, and even substrates within the same batch exhibit variations in surface characteristics such as color, gloss, and roughness. Traditional coating systems typically use a fixed set or a few preset parameters, making it difficult to effectively address these substrate variations. If changes in substrate characteristics are not adjusted promptly, the adhesion, spreadability, and penetration of white ink may be poor, affecting the final coating effect and even causing ink refusal. This requires frequent manual intervention and adjustment, which is time-consuming, labor-intensive, and yields unstable results. Furthermore, traditional roller coating or blade coating equipment often adjusts pressure or gap globally, making it difficult to differentiate control over local areas in the width direction. When there are local unevenness in the substrate (such as uneven thickness or surface defects) or when dealing with special cases such as substrate seams, it is difficult to make precise adjustments, which can easily lead to excessive or insufficient coating in local areas, resulting in uneven ink layers or defects, especially for coating high-precision, large-size substrates.

[0003] To address the aforementioned issues, this invention proposes a method for dynamically adjusting the amount of white ink coating based on real-time sensor feedback. This method enables more stable and adaptable quality control of white ink coating, improving product consistency and reducing the scrap rate. Summary of the Invention

[0004] In view of the above problems, the present invention provides a method, device and computing equipment for dynamic adjustment of white ink coating volume based on real-time sensor feedback.

[0005] According to one aspect of the present invention, a method for dynamically adjusting the amount of white ink coating based on real-time sensor feedback is provided, comprising:

[0006] Before the white ink coating station, the surface characteristic data of the substrate to be coated is acquired in real time by a multispectral sensor. The surface characteristic data includes the substrate’s color, gloss, and surface roughness index.

[0007] After the white ink coating is completed at the white ink coating station, the optical property data of the white ink coating layer are collected in real time by a high-precision spectral imager or colorimeter. The optical property data includes the Lab colorimetric value, whiteness index, hiding power and gloss of the white ink layer.

[0008] The surface characteristic data and optical characteristic data are optimized with preset target whiteness, hiding power and drying speed. The deviation between the current white ink coating amount and the target value and the ink coating amount adjustment parameters based on historical adjustment data and predicted trends are dynamically output.

[0009] The deviation between the current white ink coating amount and the target value, as well as the ink coating amount adjustment parameters based on historical adjustment data and predicted trends, are adjusted in real time by a PID controller to adjust the parameters of the white ink coating mechanism. The parameters of the white ink coating mechanism include the inkjet head ejection frequency, ink ejection amount, and roller coating pressure or doctor blade gap.

[0010] In an alternative approach, the method further includes:

[0011] Before the substrate enters the coating station, the surface of the substrate is scanned in real time by a near-infrared spectral sensor to obtain the surface energy index; the surface roughness is obtained by a laser confocal displacement sensor.

[0012] After coating, optical data of the white ink layer are collected by an online spectrophotometer. The optical data includes the hiding power index, whiteness value and curing state of the film layer. The curing state of the film layer is calculated by monitoring the surface temperature gradient with an infrared thermal imager.

[0013] In one alternative approach, the equation for calculating the cured state of the film layer is:

[0014] ;

[0015] in, The thermal conductivity of the ink; The specific heat capacity of the ink; The solvent diffusion coefficient; ; This represents the volume fraction of volatile solvents in white ink. To determine the amount of white ink applied Ink layer thickness calculated based on substrate porosity; This refers to the duration of the curing process.

[0016] In one alternative approach, the formula for generating the ink application amount adjustment parameter is:

[0017] ;

[0018] in, Whiteness control item; This refers to the drying efficiency item. This is the surface energy compensation term; , for surface energy The influence of the ink rejection probability function; The sensitivity of drying speed to coating amount; The sensitivity of whiteness to the amount of ink applied; These are the target whiteness and the actual whiteness, respectively. For temperature gradient; It indicates the energy of the substrate.

[0019] In an alternative embodiment, the method for controlling the roller coating pressure or doctor blade gap in a zonal configuration further includes:

[0020] The doctor blade is divided into multiple independent control zones with a width of ≤50mm along the width direction;

[0021] The multiple independent control regions are adjusted differentially based on the ink layer thickness distribution map generated by the hyperspectral imager.

[0022] Specifically, for any given zone, if the unevenness or steepness of the ink layer thickness within that zone is >0.3 μm / mm, then the pressure in that zone should be increased by 10-15%.

[0023] If a substrate seam is detected passing through this zone, the pressure is reduced by 50% 0.5 seconds in advance.

[0024] In an alternative approach, the method further includes:

[0025] Historical adjustment data, substrate characteristics, and ambient temperature and humidity are uploaded to the cloud platform to train a digital twin model for coating amount prediction.

[0026] When a new substrate is detected, the optimal parameter combination of similar materials is matched from the cloud and downloaded to the local controller for preloading; wherein, the real-time data of the local controller and the coating amount prediction digital twin model are synchronized with parameters every 30 minutes to realize cross-production line knowledge transfer.

[0027] In one alternative approach, the expression for the optimization objective is:

[0028] ;

[0029] in, Whiteness sensitivity; This refers to the actual measured whiteness. Target whiteness; Tolerance for whiteness fluctuations; These are the preset equation coefficients; The dynamic occlusion force safety threshold; The overall drying rate gradient; Minimum coating amount to prevent ink repulsion; The actual measured dynamic covering force; For the sensitivity of the covering force; The rate at which the covering force decreases; This represents the minimum acceptable value for the drying rate gradient; Sensitivity to drying rate gradient; For drying rate gradient tolerance; These are ink surface energy and substrate surface roughness, respectively. This represents the maximum allowable amount of white ink applied. This refers to the drying temperature. This refers to the amount of white ink applied.

[0030] According to another aspect of the present invention, a device for dynamically adjusting the amount of white ink coating based on real-time sensor feedback is provided, comprising:

[0031] The substrate characteristic detection module is used to acquire surface characteristic data of the substrate to be coated in real time through a multispectral sensor before the white ink coating station. The surface characteristic data includes the substrate's color, gloss, and surface roughness index.

[0032] The coating optical property detection module is used to collect optical property data of the white ink coating layer in real time by a high-precision spectral imager or colorimeter after the white ink coating is completed at the white ink coating station. The optical property data includes the Lab colorimetric value, whiteness index, hiding power and gloss of the white ink layer.

[0033] The intelligent decision-making and control strategy generation module is used to optimize the surface characteristic data and the optical characteristic data with preset target whiteness, hiding power and drying speed, and dynamically output the deviation between the current white ink coating amount and the target value, as well as the ink coating amount adjustment parameters based on historical adjustment data and predicted trends.

[0034] The coating mechanism execution and adjustment module is used to adjust the white ink coating mechanism parameters in real time through a PID controller, based on the deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends. The white ink coating mechanism parameters include the inkjet head ejection frequency, ink volume, and roller coating pressure or doctor blade gap.

[0035] According to another aspect of the present invention, a computing device is provided, comprising: a processor, a memory, a communication interface, and a communication bus, wherein the processor, the memory, and the communication interface communicate with each other via the communication bus;

[0036] The memory is used to store at least one executable instruction, which causes the processor to perform the operation corresponding to the above-described method for dynamic adjustment of white ink coating volume based on real-time sensor feedback.

[0037] like Figure 4 As shown, Figure 4 The upper part shows the effect of white ink coating after applying the coating solution using the method of this invention. Figure 4 The following section shows the white ink coating effect without using the present invention. According to the solution provided by the present invention, before the white ink coating station, surface characteristic data of the substrate to be coated is acquired in real time using a multispectral sensor. The surface characteristic data includes the substrate's color, gloss, and surface roughness index. After the white ink coating is completed at the white ink coating station, optical characteristic data of the white ink coating layer is acquired in real time using a high-precision spectral imager or colorimeter. The optical characteristic data includes the Lab colorimetric value, whiteness index, hiding power, and gloss of the white ink layer. The surface characteristic data and the optical characteristic data are optimized with preset target whiteness, hiding power, and drying speed as optimization targets. The deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends, are dynamically output. The deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends, are used to adjust the white ink coating mechanism parameters in real time through a PID controller. The white ink coating mechanism parameters include the inkjet head ejection frequency, inkjet volume, and roller coating pressure or doctor blade gap. This invention achieves more stable and adaptable quality control for white ink coating, improving product consistency and reducing scrap rate.

[0038] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and in order to make the above and other objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention are described below. Attached Figure Description

[0039] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings:

[0040] Figure 1 A flowchart illustrating the method for dynamic adjustment of white ink coating volume based on real-time sensor feedback according to an embodiment of the present invention is shown.

[0041] Figure 2 A schematic diagram of the framework of the white ink coating volume dynamic adjustment device based on real-time sensor feedback according to an embodiment of the present invention is shown.

[0042] Figure 3 A schematic diagram of the structure of a computing device according to an embodiment of the present invention is shown;

[0043] Figure 4 The diagram shows a comparison of the effects of implementing the present invention before and after implementation. Detailed Implementation

[0044] Exemplary embodiments of the invention will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the invention are shown in the drawings, it should be understood that the invention may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this invention will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0045] Figure 1 A flowchart illustrating a method for dynamically adjusting the amount of white ink coating based on real-time sensor feedback, according to an embodiment of the present invention, is shown. Specifically, as... Figure 1 As shown, it includes the following steps:

[0046] Step S101: Before the white ink coating station, the surface characteristic data of the substrate to be coated is acquired in real time by a multispectral sensor. The surface characteristic data includes the substrate's color, gloss, and surface roughness index.

[0047] In this embodiment, a multispectral sensor is used to acquire the color, gloss, and surface roughness of the substrate in real time. Color and gloss directly affect the final visual effect and hiding power requirements of the white ink. Surface roughness affects ink layer adhesion, leveling, and the uniformity of the final film thickness.

[0048] In an alternative approach, the method further includes:

[0049] Before the substrate enters the coating station, the surface of the substrate is scanned in real time by a near-infrared spectral sensor to obtain the surface energy index; the surface roughness is obtained by a laser confocal displacement sensor.

[0050] After coating, optical data of the white ink layer are collected by an online spectrophotometer. The optical data includes the hiding power index, whiteness value and curing state of the film layer. The curing state of the film layer is calculated by monitoring the surface temperature gradient with an infrared thermal imager.

[0051] In this embodiment, traditional roughness detection cannot directly reflect surface energy, while near-infrared spectroscopy can penetrate the surface to obtain deeper chemical information. High surface energy is beneficial for ink spreading and adhesion, while low surface energy may lead to ink repulsion or poor leveling. A laser confocal displacement sensor can provide more accurate, three-dimensional surface morphology data for acquiring surface roughness. An online spectrophotometer provides more accurate optical data with a wider spectral range.

[0052] In one alternative approach, the equation for calculating the cured state of the film layer is:

[0053] ;

[0054] in, The thermal conductivity of the ink; The specific heat capacity of the ink; The solvent diffusion coefficient; ; This represents the volume fraction of volatile solvents in white ink. To determine the amount of white ink applied Ink layer thickness calculated based on substrate porosity; This refers to the duration of the curing process.

[0055] In this embodiment, the quantification of the curing state transforms the drying and curing processes in the white ink coating process from a "black box" operation. The coating system can more precisely control subsequent drying parameters (such as temperature and airflow) based on the accurately calculated curing state, rather than relying solely on experience or simple temperature gradients, thereby ensuring curing quality. This elevates the complex curing process from simple monitoring to a calculable and predictable quantitative level. The curing state of the film can be directly calculated using the ink's thermal conductivity, specific heat capacity, solvent diffusion coefficient, volatile solvent volume fraction, ink layer thickness, and duration.

[0056] Step S102: After the white ink coating is completed at the white ink coating station, the optical property data of the white ink coating layer is collected in real time by a high-precision spectral imager or colorimeter. The optical property data includes the Lab colorimetric value, whiteness index, hiding power and gloss of the white ink layer.

[0057] In this embodiment, compared to traditional offline sampling inspection or manual visual inspection, the acquisition of key optical properties (Lab chromaticity value, whiteness index, hiding power, and gloss) of the white ink coating layer is carried out in real time and online. Once a deviation in coating quality occurs, it can be detected immediately instead of waiting until a large number of defective products are produced. Real-time detection can significantly reduce the scrapping of batch products due to quality problems, reduce production costs, and improve production efficiency.

[0058] Step S103: Using preset target whiteness, hiding power, and drying speed as optimization targets for the surface characteristic data and the optical characteristic data, dynamically output the deviation between the current white ink coating amount and the target value, as well as the ink coating amount adjustment parameters based on historical adjustment data and predicted trends.

[0059] In this embodiment, whiteness, hiding power, and drying speed are simultaneously optimized. When adjusting the ink application amount, these three key performance indicators are balanced to avoid sacrificing one parameter for another. This achieves more comprehensive coating quality control, ensuring that the product not only meets appearance (whiteness) standards but also achieves good functionality (hiding power) and production efficiency (drying speed), thus improving the overall efficiency of the coating process. The results of each adjustment are recorded to form an experience knowledge base. Machine learning is used to identify the optimal ink application amount adjustment strategy for different substrates, environmental conditions, and ink batches. If historical data shows a tendency for certain deviations under specific production conditions, fine-tuning can be made in advance to prevent problems and reduce scrap rates and rework.

[0060] In one alternative approach, the expression for the optimization objective is:

[0061] ;

[0062] in, Whiteness sensitivity; This refers to the actual measured whiteness. Target whiteness; Tolerance for whiteness fluctuations; These are the preset equation coefficients; The dynamic occlusion force safety threshold; The overall drying rate gradient; Minimum coating amount to prevent ink repulsion; The actual measured dynamic covering force; For the sensitivity of the covering force; The rate at which the covering force decreases; This represents the minimum acceptable value for the drying rate gradient; Sensitivity to drying rate gradient; For drying rate gradient tolerance; These are ink surface energy and substrate surface roughness, respectively. This represents the maximum allowable amount of white ink applied. This refers to the drying temperature. This refers to the amount of white ink applied.

[0063] In this embodiment, the optimization framework that unifies whiteness deviation, insufficient hiding power, slow drying speed, substrate characteristics, and drying temperature can more comprehensively cope with complex and ever-changing production conditions. It can shift the coating amount adjustment from passive response to active prediction and optimization, greatly reduce the need for manual intervention, and improve the automation level of the production line and the stability of the product.

[0064] Step S104: The deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends, are used to adjust the white ink coating mechanism parameters in real time through a PID controller. The white ink coating mechanism parameters include the inkjet head ejection frequency, ink volume, and roller coating pressure or doctor blade gap.

[0065] In this embodiment, the deviation between the current coating amount fed back by the sensor and the target value is input into the PID controller. The coating mechanism parameters are dynamically adjusted based on the deviation, continuously correcting errors and ensuring that the coating amount always approaches the target value. The inkjet head ejection frequency, ink volume, and roller coating pressure or doctor blade gap can be adjusted simultaneously. Multiple adjustment methods can be flexibly selected or combined according to complex actual conditions to address different substrates, different coating requirements, and various fluctuations that occur during production. For example, inkjet head parameters control the ink supply, while roller coating pressure or doctor blade gap controls the ink layer thickness and uniformity.

[0066] In one alternative approach, the formula for generating the ink application amount adjustment parameter is:

[0067] ;

[0068] in, Whiteness control item; This refers to the drying efficiency item. This is the surface energy compensation term; , for surface energy The influence of the ink rejection probability function; The sensitivity of drying speed to coating amount; The sensitivity of whiteness to the amount of ink applied; These are the target whiteness and the actual whiteness, respectively. For temperature gradient; It indicates the energy of the substrate.

[0069] In this embodiment, the sensitivity of whiteness to ink application amount and the sensitivity of drying speed to ink application amount are not simply adjusted based on the magnitude of the deviation, but rather the degree of adjustment is determined by the efficiency with which whiteness or drying speed changes with ink application amount. For example, if whiteness is highly sensitive to ink application amount, even a small change in ink application amount can lead to a significant change in whiteness, then a more refined adjustment is made. By quantifying the drying and ink repulsion phenomena during the coating process, adjustments are no longer based on experience or simple threshold judgments, but on scientific and calculable principles, thus improving the accuracy and reliability of the adjustments.

[0070] In an alternative embodiment, the method for controlling the roller coating pressure or doctor blade gap in a zonal configuration further includes:

[0071] The doctor blade is divided into multiple independent control zones with a width of ≤50mm along the width direction;

[0072] The multiple independent control regions are adjusted differentially based on the ink layer thickness distribution map generated by the hyperspectral imager.

[0073] Specifically, for any given zone, if the unevenness or steepness of the ink layer thickness within that zone is >0.3 μm / mm, then the pressure in that zone should be increased by 10-15%.

[0074] If a substrate seam is detected passing through this zone, the pressure is reduced by 50% 0.5 seconds in advance.

[0075] In this embodiment, the doctor blade is divided into multiple independent control zones with a width ≤ 50 mm along the width direction, upgrading the coating control from traditional overall adjustment to local adjustment. In wide-width coating, there may be local differences in substrate surface characteristics and coating environment, making it difficult for overall adjustment to meet the needs of each area. Zoned control can solve this problem and improve coating uniformity. Based on the ink layer thickness distribution map generated by the hyperspectral imager, each independent control zone is adjusted differently, which can identify areas of uneven coating and make targeted adjustments. The unevenness or steepness of change in ink layer thickness > 0.3 μm / mm is used as the trigger condition for adjustment, which can detect local deviations in ink layer thickness in real time and determine whether intervention is needed based on a preset threshold. Once the unevenness exceeds the standard, the pressure of the zone is immediately increased by 10-15% to correct it, which can effectively suppress the fluctuation of ink layer thickness. The substrate seam is detected passing through the zone and a response is made 0.5 seconds in advance. The substrate seam is a common disturbance factor in the coating process. If it is not dealt with in time, it may lead to ink accumulation, breakage or severe unevenness. For seams, reducing the pressure by 50% can effectively prevent ink layer stacking, doctor blade damage, or coating defects caused by excessive pressure at the seams, thereby reducing scrap rate, improving production efficiency and equipment life, which is significantly better than traditional passive correction.

[0076] In an alternative approach, the method further includes:

[0077] Historical adjustment data, substrate characteristics, and ambient temperature and humidity are uploaded to the cloud platform to train a digital twin model for coating amount prediction.

[0078] When a new substrate is detected, the optimal parameter combination of similar materials is matched from the cloud and downloaded to the local controller for preloading; wherein, the real-time data of the local controller and the coating amount prediction digital twin model are synchronized with parameters every 30 minutes to realize cross-production line knowledge transfer.

[0079] In this embodiment, the cloud platform serves as a central knowledge base, storing historical data and optimization experiences from different production lines and equipment. Real-time data from the local controller is synchronized with the coating quantity prediction digital twin model every 30 minutes, enabling cross-production line knowledge transfer. Experience gained by one production line in solving a specific problem or optimizing a process parameter can be quickly synchronized to the cloud model and shared with other production lines, even applied to factories in different regions. This greatly promotes internal technical knowledge sharing and collaborative innovation, avoids repeated trial and error, and improves overall operational efficiency.

[0080] According to the solution provided by the present invention, before the white ink coating station, surface characteristic data of the substrate to be coated is acquired in real time using a multispectral sensor. The surface characteristic data includes the substrate's color, gloss, and surface roughness index. After the white ink coating is completed at the white ink coating station, optical characteristic data of the white ink coating layer is acquired in real time using a high-precision spectral imager or colorimeter. The optical characteristic data includes the Lab colorimetric value, whiteness index, hiding power, and gloss of the white ink layer. The surface characteristic data and the optical characteristic data are optimized with preset target whiteness, hiding power, and drying speed as optimization targets. The deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends, are dynamically output. The deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends, are used to adjust the white ink coating mechanism parameters in real time through a PID controller. The white ink coating mechanism parameters include the inkjet head ejection frequency, ink volume, and roller coating pressure or doctor blade gap. This invention achieves more stable and adaptable white ink coating quality control, improves product consistency, and reduces the scrap rate.

[0081] Figure 2 A schematic diagram of the framework of a white ink coating volume dynamic adjustment device based on real-time sensor feedback according to an embodiment of the present invention is shown. The white ink coating volume dynamic adjustment device based on real-time sensor feedback includes:

[0082] The substrate characteristic detection module 210 is used to acquire surface characteristic data of the substrate to be coated in real time through a multispectral sensor before the white ink coating station. The surface characteristic data includes the substrate's color, gloss, and surface roughness index.

[0083] The coating optical property detection module 220 is used to collect optical property data of the white ink coating layer in real time by a high-precision spectral imager or colorimeter after the white ink coating is completed at the white ink coating station. The optical property data includes the Lab colorimetric value, whiteness index, hiding power and gloss of the white ink layer.

[0084] The intelligent decision-making and control strategy generation module 230 is used to dynamically output the deviation between the current white ink coating amount and the target value, as well as the ink coating amount adjustment parameters based on historical adjustment data and predicted trends, based on the preset target whiteness, hiding power and drying speed of the surface characteristic data and the optical characteristic data.

[0085] The coating mechanism execution and adjustment module 240 is used to adjust the white ink coating mechanism parameters in real time through a PID controller based on the deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends. The white ink coating mechanism parameters include the inkjet head ejection frequency, ink ejection amount, and roller coating pressure or doctor blade gap.

[0086] Figure 3 The diagram shows a structural schematic of an embodiment of the computing device of the present invention. The specific embodiments of the present invention do not limit the specific implementation of the computing device.

[0087] like Figure 3 As shown, the computing device may include: a processor 302, a communications interface 304, a memory 306, and a communications bus 308.

[0088] The processor 302, communication interface 304, and memory 306 communicate with each other via communication bus 308. Communication interface 304 is used to communicate with other network elements such as clients or other servers. The processor 302 executes program 310, specifically performing the relevant steps in the above-described embodiment of the dynamic adjustment method for white ink coating volume based on real-time sensor feedback.

[0089] Specifically, program 310 may include program code that includes computer operation instructions.

[0090] Processor 302 may be a central processing unit (CPU), an application-specific integrated circuit (ASIC), or one or more integrated circuits configured to implement embodiments of the present invention. The computing device includes one or more processors, which may be processors of the same type, such as one or more CPUs; or processors of different types, such as one or more CPUs and one or more ASICs.

[0091] Memory 306 is used to store program 310. Memory 306 may include high-speed RAM memory, and may also include non-volatile memory, such as at least one disk storage device.

[0092] According to the solution provided by the present invention, before the white ink coating station, surface characteristic data of the substrate to be coated is acquired in real time using a multispectral sensor. The surface characteristic data includes the substrate's color, gloss, and surface roughness index. After the white ink coating is completed at the white ink coating station, optical characteristic data of the white ink coating layer is acquired in real time using a high-precision spectral imager or colorimeter. The optical characteristic data includes the Lab colorimetric value, whiteness index, hiding power, and gloss of the white ink layer. The surface characteristic data and the optical characteristic data are optimized with preset target whiteness, hiding power, and drying speed as optimization targets. The deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends, are dynamically output. The deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends, are used to adjust the white ink coating mechanism parameters in real time through a PID controller. The white ink coating mechanism parameters include the inkjet head ejection frequency, ink volume, and roller coating pressure or doctor blade gap. This invention achieves more stable and adaptable white ink coating quality control, improves product consistency, and reduces the scrap rate.

[0093] Those skilled in the art will understand that modules in the device of the embodiments can be adaptively changed and placed in one or more devices different from that embodiment. Modules, units, or components in the embodiments can be combined into a single module, unit, or component, and further, they can be divided into multiple sub-modules, sub-units, or sub-components. Except where at least some of such features and / or processes or units are mutually exclusive, any combination of all features disclosed in this specification (including the accompanying claims, abstract, and drawings) and all processes or units of any method or device so disclosed can be employed. Unless expressly stated otherwise, each feature disclosed in this specification (including the accompanying claims, abstract, and drawings) may be replaced by an alternative feature that serves the same, equivalent, or similar purpose. Furthermore, those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of the invention and form different embodiments. For example, in the following claims, any of the claimed embodiments can be used in any combination. The invention can be implemented by means of hardware comprising several different elements and by means of a suitably programmed computer. In the unit claims listing several devices, several of these devices may be embodied by the same hardware item. Unless otherwise specified, the steps in the above embodiments should not be construed as limiting the order of execution.

Claims

1. A method for dynamically adjusting the amount of white ink coating based on real-time sensor feedback, characterized in that, include: Before the white ink coating station, the surface characteristic data of the substrate to be coated is acquired in real time by a multispectral sensor. The surface characteristic data includes the substrate’s color, gloss, and surface roughness index. After the white ink coating is completed at the white ink coating station, the optical property data of the white ink coating layer are collected in real time by a high-precision spectral imager or colorimeter. The optical property data includes the Lab colorimetric value, whiteness index, hiding power and gloss of the white ink layer. The surface characteristic data and optical characteristic data are optimized with preset target whiteness, hiding power and drying speed. The deviation between the current white ink coating amount and the target value and the ink coating amount adjustment parameters based on historical adjustment data and predicted trends are dynamically output. The deviation between the current white ink coating amount and the target value, as well as the ink coating amount adjustment parameters based on historical adjustment data and predicted trends, are adjusted in real time by a PID controller to adjust the parameters of the white ink coating mechanism. The parameters of the white ink coating mechanism include the inkjet head ejection frequency, ink ejection amount, and roller coating pressure or doctor blade gap.

2. The method for dynamic adjustment of white ink coating volume based on real-time sensor feedback according to claim 1, characterized in that, The method further includes: Before the substrate enters the coating station, the surface of the substrate is scanned in real time by a near-infrared spectral sensor to obtain the surface energy index; the surface roughness is obtained by a laser confocal displacement sensor. After coating, optical data of the white ink layer are collected by an online spectrophotometer. The optical data includes the hiding power index, whiteness value and curing state of the film layer. The curing state of the film layer is calculated by monitoring the surface temperature gradient with an infrared thermal imager.

3. The method for dynamic adjustment of white ink coating volume based on real-time sensor feedback according to claim 2, characterized in that, The equation for calculating the cured state of the film layer is as follows: ； in, The thermal conductivity of the ink; The specific heat capacity of the ink; The solvent diffusion coefficient; ; This represents the volume fraction of volatile solvents in white ink. To determine the amount of white ink applied Ink layer thickness calculated based on substrate porosity; This refers to the duration of the curing process.

4. The method for dynamic adjustment of white ink coating volume based on real-time sensor feedback according to claim 1, characterized in that, The formula for generating the ink application amount adjustment parameter is as follows: ； in, Whiteness control item; This refers to the drying efficiency item. This is the surface energy compensation term; , for surface energy The influence of the ink rejection probability function; The sensitivity of drying speed to coating amount; The sensitivity of whiteness to the amount of ink applied; These are the target whiteness and the actual whiteness, respectively. For temperature gradient; It indicates the energy of the substrate.

5. The method for dynamic adjustment of white ink coating volume based on real-time sensor feedback according to claim 1, characterized in that, The method for controlling the roller coating pressure or the doctor blade gap further includes: The doctor blade is divided into multiple independent control zones with a width of ≤50mm along the width direction; The multiple independent control regions are adjusted differentially based on the ink layer thickness distribution map generated by the hyperspectral imager. Specifically, for any given zone, if the unevenness or steepness of the ink layer thickness within that zone is >0.3 μm / mm, then the pressure in that zone should be increased by 10-15%. If a substrate seam is detected passing through this zone, the pressure is reduced by 50% 0.5 seconds in advance.

6. The method for dynamic adjustment of white ink coating volume based on real-time sensor feedback according to claim 1, characterized in that, The method further includes: Historical adjustment data, substrate characteristics, and ambient temperature and humidity are uploaded to the cloud platform to train a digital twin model for coating amount prediction. When a new substrate is detected, the optimal parameter combination of similar materials is matched from the cloud and downloaded to the local controller for preloading; wherein, the real-time data of the local controller and the coating amount prediction digital twin model are synchronized with parameters every 30 minutes to realize cross-production line knowledge transfer.

7. The method for dynamic adjustment of white ink coating volume based on real-time sensor feedback according to claim 1, characterized in that, The expression for the optimization objective is: ； in, Whiteness sensitivity; This refers to the actual measured whiteness. Target whiteness; Tolerance for whiteness fluctuations; These are the preset equation coefficients; The dynamic occlusion force safety threshold; The overall drying rate gradient; Minimum coating amount to prevent ink repulsion; The actual measured dynamic covering force; For the sensitivity of the covering force; The rate at which the covering force decreases; This represents the minimum acceptable value for the drying rate gradient; Sensitivity to drying rate gradient; For drying rate gradient tolerance; These are ink surface energy and substrate surface roughness, respectively. This represents the maximum allowable amount of white ink applied. This refers to the drying temperature. This refers to the amount of white ink applied.

8. A device for dynamically adjusting the amount of white ink coating based on real-time sensor feedback, characterized in that, include: The substrate characteristic detection module is used to acquire surface characteristic data of the substrate to be coated in real time through a multispectral sensor before the white ink coating station. The surface characteristic data includes the substrate's color, gloss, and surface roughness index. The coating optical property detection module is used to collect optical property data of the white ink coating layer in real time by a high-precision spectral imager or colorimeter after the white ink coating is completed at the white ink coating station. The optical property data includes the Lab colorimetric value, whiteness index, hiding power and gloss of the white ink layer. The intelligent decision-making and control strategy generation module is used to optimize the surface characteristic data and the optical characteristic data with preset target whiteness, hiding power and drying speed, and dynamically output the deviation between the current white ink coating amount and the target value, as well as the ink coating amount adjustment parameters based on historical adjustment data and predicted trends. The coating mechanism execution and adjustment module is used to adjust the white ink coating mechanism parameters in real time through a PID controller, based on the deviation between the current white ink coating amount and the target value, as well as the ink amount adjustment parameters based on historical adjustment data and predicted trends. The white ink coating mechanism parameters include the inkjet head ejection frequency, ink volume, and roller coating pressure or doctor blade gap.

9. A computing device, comprising: The processor, memory, communication interface, and communication bus are provided, wherein the processor, memory, and communication interface communicate with each other via the communication bus. The memory is used to store at least one executable instruction, which causes the processor to perform the operation corresponding to any one of the above claims 1-7, the method for dynamic adjustment of white ink coating volume based on real-time sensor feedback.

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