Traceable rubber tube size out-of-tolerance automatic marking system

Abstract

The invention discloses a traceable rubber tube size out-of-tolerance automatic marking system. The system comprises a size detection module; a data transmission and processing module; a prediction model module; predicting whether the size of the rubber tube is about to be out of tolerance, and outputting a prediction result; a process parameter adjusting module; when the prediction model module predicts that the size of the rubber tube is about to be out of tolerance, the process parameter adjustment module automatically adjusts process parameters of an extrusion production line according to a preset adjustment strategy; a code spraying marking module; when it is judged that the size of the rubber tube is out of tolerance, the code spraying equipment is controlled to stop spraying codes at a set distance point, and the rubber tube without code spraying subsequently is a product with the out-of-tolerance size; and an abnormity recording and tracing module. And quality tracing is supported. According to the invention, through the full-process closed-loop management from detection, early warning and adjustment to tracing, the production quality of the rubber tube is improved.

Description

Technical Field

[0001] The invention belongs to the field of out-of-tolerance automatic marking systems, and in particular relates to a traceable out-of-tolerance automatic marking system for hose sizes. Background Art

[0002] In the precision manufacturing process of hose extrusion, dimensional errors constantly affect product quality and performance, including the following issues:

[0003] 1. When the fluidity of the raw materials fluctuates, it is difficult to maintain a stable extrusion pressure. The unstable pressure makes it impossible for the hose to be formed according to the predetermined size specifications during the extrusion process, resulting in dimensional errors.

[0004] Second, during long-term use, the mold will inevitably wear out. This wear causes the shape and size of the mold to change. During the heating process, the temperature difference between different parts of the mold will make the flow rate and cooling rate of the raw material in the mold inconsistent, resulting in deviations in the size of each part of the extruded hose.

[0005] Third, the haul-off speed is not well matched to the extrusion rate. If the haul-off speed is too fast, the hose will be stretched, resulting in a smaller diameter and thinner wall thickness. Conversely, if the haul-off speed is too slow, the hose will be piled up, resulting in an increased diameter and thicker wall thickness. This mismatch is like loose gear meshing, preventing the entire production process from running smoothly, resulting in dimensional errors.

[0006] 4. Manual sampling is inefficient. Faced with continuously produced hoses, only a small number of samples can be taken for testing, making it difficult to fully and timely discover dimensional errors. Real-time correction is impossible, and when dimensional errors are discovered, a large number of unqualified products may have already been produced, resulting in a waste of resources and increased costs. Summary of the Invention

[0007] The purpose of the present invention is to propose a traceable automatic marking system for hose size deviations in order to solve the problems in current hose extrusion production, such as unstable extrusion pressure caused by fluctuations in raw material fluidity, mold wear or uneven temperature distribution, mismatch between tractor speed and extrusion rate, and low efficiency of manual sampling, which make it impossible to achieve real-time correction and lead to errors in hose size.

[0008] In order to achieve the above object, the present invention adopts the following technical solution: a traceable hose size out-of-tolerance automatic marking system, comprising:

[0009] Size detection module: Use X-ray diameter gauge to detect the size parameters of the hose on the extrusion production line in real time;

[0010] Data transmission and processing module; connected to the size detection module, for receiving and processing the x

[0011] -Dimensional data detected by ray caliper;

[0012] Prediction model module: trained based on historical hose extrusion production data, it can predict whether the hose size is about to exceed the tolerance based on the currently detected dimensional data and process parameters, and output the prediction results;

[0013] a process parameter adjustment module connected to the prediction model module, and when the prediction model module predicts that the hose dimension is about to be out of tolerance, the process parameter adjustment module automatically adjusts the process parameters of the extrusion production line according to a preset adjustment strategy, the process parameters including at least one of extrusion pressure, die temperature, and tractor speed;

[0014] A coding marking module connected to the data transmission and processing module includes a coding device and a control unit. The control unit determines whether the hose size is out of tolerance based on the size data transmitted by the data transmission and processing module. When the hose size is determined to be out of tolerance, the coding device is controlled to stop coding at a set distance point. The hose that is not subsequently coded is a product with out-of-tolerance size.

[0015] and an abnormality recording and tracing module; connected to the data transmission and processing module, for automatically recording the timestamp, relevant process parameters and out-of-tolerance size data of the hose size out-of-tolerance event, and storing these data in a database to support quality tracing.

[0016] As a further description of the above technical solution:

[0017] A temperature sensor and a pressure sensor are also provided, wherein the temperature sensor is used to detect the temperature distribution of the mold, and the pressure sensor is used to detect the extrusion pressure.

[0018] As a further description of the above technical solution:

[0019] The data transmission and processing module adopts a multi-sensor data fusion algorithm.

[0020] As a further description of the above technical solution:

[0021] The abnormality recording and tracing module also includes a data visualization unit, which is used to visualize the timestamps, relevant process parameters and out-of-tolerance size data of the hose size out-of-tolerance events stored in the database in the form of charts, reports, etc.

[0022] As a further description of the above technical solution:

[0023] It also includes a communication module, which is used to synchronously push the abnormal records and the relevant data of the hose size out-of-tolerance event recorded by the traceability module to an external quality management system or user terminal device, so that relevant personnel can obtain quality abnormality information in a timely manner and handle it.

[0024] As a further description of the above technical solution:

[0025] The X-ray caliper includes an automatic calibration module to regularly calibrate the measurement accuracy to ensure the accuracy of the measurement data.

[0026] As a further description of the above technical solution:

[0027] The coding device in the coding marking module adopts non-contact coding technology. The coding content includes product batch number, production time and size deviation identification information. The size deviation identification information is distinguished by specific symbols or colors.

[0028] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0029] 1. In the present invention, on the hose extrusion production line, an X-ray caliper scans the hose size in real time with an ultra-high precision of ±0.01mm, and its data is transmitted to the data processing module; at the same time, the temperature sensor and the pressure sensor synchronously collect key parameters such as mold temperature and extrusion pressure, and deeply analyze them through the multi-sensor data fusion algorithm to form the entire hose production status; the prediction model module is trained based on historical big data to predict the risk of dimensional deviation in advance. When the risk of deviation occurs, an instruction is sent to the process parameter adjustment module to adjust the parameters such as extrusion pressure, mold temperature or traction machine speed before the dimension deviation occurs; if the dimension is still out of tolerance, the inkjet marking module is immediately started and the inkjet marking is stopped accurately at the preset distance point to mark the out-of-tolerance hose. At the same time, the out-of-tolerance data is synchronously pushed to the abnormal recording and tracing module, which automatically records the timestamp, process parameters and dimensional data of the deviation event, builds a traceable database, realizes the closed-loop management of the entire process from detection, early warning, adjustment to tracing, and improves the quality of hose production. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0031] Figure 1 This is a flowchart of a traceable automatic marking system for hose size deviations. DETAILED DESCRIPTION

[0032] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0034] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort shall fall within the scope of protection of the present invention.

[0035] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0036] In the description of the embodiments of the present invention, it should be noted that the terms "upper" and "inner" etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are orientations or positional relationships in which the inventive product is usually placed when in use. These are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they should not be understood as limitations on the present invention.

[0037] In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood broadly. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to direct connections, indirect connections through an intermediate medium, or internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0038] See also Figure 1 The present invention provides a technical solution: a traceable hose size out-of-tolerance automatic marking system, comprising:

[0039] Size detection module: Use X-ray diameter gauge to detect the size parameters of the hose on the extrusion production line in real time;

[0040] Data transmission and processing module; connected to the size detection module, for receiving and processing the size data detected by the X-ray caliper;

[0041] Prediction model module: trained based on historical hose extrusion production data, it can predict whether the hose size is about to exceed the tolerance based on the currently detected dimensional data and process parameters, and output the prediction results;

[0042] a process parameter adjustment module connected to the prediction model module, and when the prediction model module predicts that the hose dimension is about to be out of tolerance, the process parameter adjustment module automatically adjusts the process parameters of the extrusion production line according to a preset adjustment strategy, the process parameters including at least one of extrusion pressure, die temperature, and tractor speed;

[0043] A coding marking module connected to the data transmission and processing module includes a coding device and a control unit. The control unit determines whether the hose size is out of tolerance based on the size data transmitted by the data transmission and processing module. When the hose size is determined to be out of tolerance, the coding device is controlled to stop coding at a set distance point. The hose that is not subsequently coded is a product with out-of-tolerance size.

[0044] and an abnormality recording and tracing module; connected to the data transmission and processing module, for automatically recording the timestamp, relevant process parameters and out-of-tolerance size data of the hose size out-of-tolerance event, and storing these data in a database to support quality tracing.

[0045] The automatic adjustment according to the preset adjustment strategy in the process parameter adjustment module mainly includes:

[0046] When it is predicted that the hose size is about to exceed the tolerance due to unstable extrusion pressure caused by fluctuations in raw material fluidity, the process parameter adjustment module adjusts the extrusion pressure of the extruder by adjusting the screw speed or feed rate of the extruder to stabilize the extrusion pressure;

[0047] When it is predicted that the hose dimensions are about to exceed tolerance due to mold wear or uneven temperature distribution, the process parameter adjustment module adjusts the mold temperature and optimizes the mold temperature distribution by controlling the power of the mold heating device. At the same time, it can prompt the user to perform mold maintenance or replacement based on the mold wear condition.

[0048] When it is predicted that the hose size is about to exceed the tolerance due to the mismatch between the tractor speed and the extrusion rate, the process parameter adjustment module adjusts the tractor speed to match the tractor speed with the extrusion rate.

[0049] A temperature sensor and a pressure sensor are also provided, wherein the temperature sensor is used to detect the temperature distribution of the mold, and the pressure sensor is used to detect the extrusion pressure.

[0050] The data transmission and processing module adopts a multi-sensor data fusion algorithm; the size data detected by the X-ray caliper, the temperature data detected by the temperature sensor, and the pressure data detected by the pressure sensor are fused and processed to obtain more accurate hose production status information, thereby improving the accuracy of judging hose size deviations.

[0051] The abnormality recording and tracing module also includes a data visualization unit, which is used to visualize the timestamps, relevant process parameters and out-of-tolerance size data of hose size out-of-tolerance events stored in the database in the form of charts, reports, etc., so that users can intuitively understand the quality problems and distribution in the hose production process.

[0052] It also includes a communication module, which is used to synchronously push the abnormal records and the relevant data of the hose size out-of-tolerance event recorded by the traceability module to an external quality management system or user terminal device, so that relevant personnel can obtain quality abnormality information in a timely manner and handle it.

[0053] The X-ray caliper includes an automatic calibration module to regularly calibrate the measurement accuracy to ensure the accuracy of the measurement data. The X-ray caliper is installed at a key position on the extrusion production line, which can ensure that the dimensional changes of the hose are detected in a timely and accurate manner during the hose extrusion process.

[0054] The coding device in the coding marking module adopts non-contact coding technology. The coding content includes product batch number, production time and size deviation identification information. The size deviation identification information is distinguished by specific symbols or colors so that hoses with size deviation can be quickly identified in the subsequent product circulation process.

[0055] In the inkjet marking module, the control unit controls the deviation of the hose size by:

[0056] Preset a normal range threshold, a warning threshold, and a shutdown threshold for the size. The normal range threshold is the qualified range of the hose size, and the warning threshold and the shutdown threshold constitute multiple thresholds.

[0057] When the detected hose size exceeds the normal range threshold but does not reach the warning threshold, the control unit sends a warning signal but does not control the inkjet printer to stop inkjet printing;

[0058] When the detected hose size reaches or exceeds the warning threshold, the control unit starts to record the out-of-tolerance related information, and when the shutdown threshold is reached, controls the inkjet printer to stop inkjet printing at a set distance point, and sends an adjustment signal to the process parameter adjustment module.

[0059] This module can directly judge the data of the data transmission and processing module, and can also judge the data after process adjustment to avoid abnormalities or delays in the process adjustment module. In general, it summarizes and judges the data transmitted to the inkjet marking module to avoid abnormal marking.

[0060] Working principle: On the hose extrusion production line, the X-ray diameter gauge scans the hose size in real time with an ultra-high precision of ±0.01mm, and its data is transmitted to the data processing module; at the same time, the temperature sensor and pressure sensor synchronously collect key parameters such as mold temperature and extrusion pressure, and deeply analyze them through the multi-sensor data fusion algorithm to form the entire hose production status; the prediction model module is trained based on historical big data to predict the risk of dimensional deviation in advance. When the risk of deviation occurs, it sends instructions to the process parameter adjustment module to adjust the parameters such as extrusion pressure, mold temperature or traction machine speed before the dimension deviation occurs; if the dimension is still out of tolerance, the inkjet marking module starts immediately and stops spraying accurately at the preset distance point to mark the out-of-tolerance hose. At the same time, the out-of-tolerance data is synchronously pushed to the abnormal recording and tracing module, which automatically records the timestamp, process parameters and dimensional data of the deviation event, builds a traceable database, and realizes closed-loop management of the entire process from detection, early warning, adjustment to traceability, thereby improving the quality of hose production.

[0061] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A traceable hose size out-of-tolerance automatic marking system, characterized by: include: Size detection module: Use X-ray diameter gauge to detect the size parameters of the hose on the extrusion production line in real time; Data transmission and processing module; connected to the size detection module, and configured to receive and process the size data detected by the X-ray caliper; Prediction model module: trained based on historical hose extrusion production data, it can predict whether the hose size is about to exceed the tolerance based on the currently detected dimensional data and process parameters, and output the prediction results; Process parameter adjustment module; The process parameter adjustment module is connected to the prediction model module, and when the prediction model module predicts that the hose size is about to be out of tolerance, the process parameter adjustment module automatically adjusts the process parameters of the extrusion production line according to a preset adjustment strategy, the process parameters including at least one of extrusion pressure, mold temperature, and tractor speed; A coding marking module connected to the data transmission and processing module includes a coding device and a control unit. The control unit determines whether the hose size is out of tolerance based on the size data transmitted by the data transmission and processing module. When the hose size is determined to be out of tolerance, the coding device is controlled to stop coding at a set distance point. The hose that is not subsequently coded is a product with out-of-tolerance size. and an abnormality recording and tracing module; connected to the data transmission and processing module, for automatically recording the timestamp, relevant process parameters and out-of-tolerance size data of the hose size out-of-tolerance event, and storing these data in a database to support quality tracing.

2. The traceable hose size out-of-tolerance automatic marking system according to claim 1 is characterized in that: A temperature sensor and a pressure sensor are also provided, wherein the temperature sensor is used to detect the temperature distribution of the mold, and the pressure sensor is used to detect the extrusion pressure.

3. The traceable hose size out-of-tolerance automatic marking system according to claim 2 is characterized in that: The data transmission and processing module adopts a multi-sensor data fusion algorithm.

4. The traceable hose size out-of-tolerance automatic marking system according to claim 3 is characterized in that: The abnormality recording and tracing module also includes a data visualization unit, which is used to visualize the timestamps, relevant process parameters and out-of-tolerance size data of the hose size out-of-tolerance events stored in the database in the form of charts, reports, etc.

5. The traceable hose size out-of-tolerance automatic marking system according to claim 1 is characterized in that: It also includes a communication module, which is used to synchronously push the abnormal records and the relevant data of the hose size out-of-tolerance event recorded by the traceability module to an external quality management system or user terminal device, so that relevant personnel can obtain quality abnormality information in a timely manner and handle it.

6. The traceable hose size out-of-tolerance automatic marking system according to claim 1 is characterized in that: The X-ray caliper includes an automatic calibration module to regularly calibrate the measurement accuracy to ensure the accuracy of the measurement data.

7. The traceable hose size out-of-tolerance automatic marking system according to claim 1 is characterized in that: The coding device in the coding marking module adopts non-contact coding technology. The coding content includes product batch number, production time and size deviation identification information. The size deviation identification information is distinguished by specific symbols or colors.

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