Screen printing auxiliary plate

Abstract

The invention relates to the technical field of silk-screen printing equipment, and discloses a silk-screen printing auxiliary plate which is applied to a silk-screen printing machine, the silk-screen printing machine comprises a silk-screen platform, a conveying belt and a lifting side table, and the lifting side table is provided with a side table groove rail; the silk-screen printing auxiliary plate is fixedly connected with the lifting side table through the fixing holes and threads, and the silk-screen printing auxiliary plate can move front and back on the lifting side table along the side table groove track. The sensor module is used for collecting size data, position data and height difference data of to-be-printed glass in real time; the driving mechanism is used for driving the screen printing auxiliary plate to move along the side table groove track or lift along with the lifting side table; the control unit calls the corresponding position parameters according to the size data collected by the sensor module and controls the driving mechanism to drive the screen printing auxiliary plate to move to the target position, so that the screen printing auxiliary plate is flush with the screen printing platform and the glass surface during printing. And the requirements of high precision and high efficiency of high-end colored glazed glass production are met.

Description

Technical Field

[0001] The present application relates to the technical field of screen printing equipment, and in particular to a screen printing auxiliary plate. Background Art

[0002] During screen printing on enameled glass, the screen size is typically larger than the glass, leaving a transition section between the front and back ends of the glass and the screen. If the lower portion of this transition section is suspended, the "bump-like" structure at the front and the "downhill" structure at the end can cause wear and tear on the screen during squeegee printing, resulting in cosmetic defects such as jitter and bounce marks. The traditional solution involves attaching rubber pads to the front and back ends of the screen and securing them with tape to fill the transition section. However, this approach has significant drawbacks: 1. Unreliable fixation: The rubber pad relies on transparent tape to connect to the screen. Due to the friction of the squeegee, it is easy to loosen, move, or even fall off, resulting in white spots on the glass or scratches on the surface. 2. Poor material adaptability: The hardness of the rubber pad is significantly different from that of the glass, and there is still a sudden change in stiffness in the transition section. When the scraping pressure changes, it is easy to cause the mesh to shake, resulting in an uneven glaze layer; 3. Low operating efficiency: Each printing requires manual pasting of tape and calibration of the rubber pad position. After printing, the residual glue marks on the mesh need to be cleaned, which consumes a lot of screen washing water and manpower, and cannot adapt to the rapid switching of multiple sizes of glass.

[0003] In the existing technology, improvements to the transition section defects only remain at the mechanical fixation level (such as optimizing the rubber pad material or pasting method), and the following core problems are not solved: lack of automatic adaptation capability to glass of different sizes, requiring manual measurement and adjustment of the auxiliary pad position; inability to perceive pressure changes during the printing process in real time and dynamically compensate for the elastic deformation of the mesh, resulting in uncontrollable jitter errors; reliance on disposable consumables (tape, rubber pads), resulting in material waste and environmental pollution problems.

[0004] Therefore, the existing technology has not yet proposed a screen printing auxiliary device that integrates adaptive size adjustment, highly intelligent calibration and dynamic error compensation, which makes it difficult to meet the high-precision and high-efficiency requirements of high-end colored glaze glass production. Summary of the Invention

[0005] This application provides a screen printing auxiliary plate, which aims to solve the problem that the existing technology has not yet proposed a screen printing auxiliary device that integrates adaptive size adjustment, highly intelligent calibration and dynamic error compensation, and it is difficult to meet the high-precision and high-efficiency requirements of high-end colored glaze glass production.

[0006] In a first aspect, the present application provides a screen printing auxiliary plate, which is applied to a screen printing machine, the screen printing machine comprising a screen printing platform, a transmission belt, and a lifting side platform, wherein the lifting side platform is provided with a side platform groove track; the screen printing auxiliary plate is fixedly connected to the lifting side platform via a fixing hole via a thread, and the screen printing auxiliary plate can move back and forth on the lifting side platform along the side platform groove track; the screen printing machine further comprises: A sensor module is used to collect the size data and position data of the glass to be printed and the height difference data between the screen printing auxiliary plate and the screen printing platform in real time; A driving mechanism connected to the screen printing auxiliary plate, used for driving the screen printing auxiliary plate to move along the side stage groove track or to rise and fall with the lifting side stage; The control unit pre-stores auxiliary plate position parameters and height matching parameters corresponding to different glass sizes, calls the corresponding position parameters according to the size data collected by the sensor module, controls the driving mechanism to drive the screen printing auxiliary plate to move to the target position, and controls the lifting side platform to drive the screen printing auxiliary plate to move up and down according to the height difference data, so that the screen printing auxiliary plate is flush with the screen printing platform and the glass surface during printing; the control unit dynamically adjusts the position of the screen printing auxiliary plate according to the pressure data collected in real time during the scraper printing process to compensate for the transition section jitter error caused by the elastic deformation of the mesh.

[0007] In some embodiments, the sensor module includes a visual sensor, a photoelectric sensor and a displacement sensor; the visual sensor is used to collect the length and width dimension data of the glass to be printed, the photoelectric sensor is used to collect the position data of the glass to be printed on the transmission belt, and the displacement sensor is used to monitor the height difference data between the screen printing auxiliary plate and the screen printing platform in real time.

[0008] In some embodiments, the driving mechanism includes a servo motor, a screw nut assembly and a lifting cylinder. The servo motor is connected to the screw nut assembly to drive the screen printing auxiliary plate to move back and forth along the side stage groove track. The lifting cylinder is connected to the lifting side stage to drive the lifting side stage to drive the screen printing auxiliary plate to rise and fall.

[0009] Exemplarily, the auxiliary plate position parameters pre-stored in the control unit include forward and backward movement distance data corresponding to the length of the glass; the corresponding position parameters are called according to the size data collected by the sensor module, and the driving mechanism is controlled to drive the screen printing auxiliary plate to move to the target position, including: according to the glass length data collected by the visual sensor, the corresponding forward and backward movement distance is matched from the preset database, and a driving signal is generated to control the servo motor to drive the screen printing auxiliary plate to move to the target position.

[0010] Exemplarily, the position of the screen printing auxiliary plate is dynamically adjusted according to the pressure data collected in real time during the squeegee printing process to compensate for the transition section jitter error caused by the elastic deformation of the mesh, including: obtaining printing pressure data collected in real time by a pressure sensor arranged on the squeegee or the screen, and when the pressure data fluctuation exceeds a preset threshold, controlling the servo motor to drive the screen printing auxiliary plate to move slightly toward the direction close to the glass, and the moving distance is positively correlated with the elastic deformation of the mesh to compensate for the transition section jitter error.

[0011] In some embodiments, the lifting side platform is controlled according to the height difference data to drive the screen printing auxiliary plate to rise and fall, so that the screen printing auxiliary plate is flush with the screen printing platform and the glass surface during printing, including: adjusting the stroke of the lifting cylinder according to the height difference data fed back in real time by the displacement sensor until the upper surface of the screen printing auxiliary plate is in the same horizontal plane as the upper surface of the screen printing platform and the upper surface of the glass to be printed.

[0012] In some embodiments, the screen printing auxiliary plate is made of insulating bakelite or aluminum alloy plate, the hardness difference between the screen printing auxiliary plate and the hardness of the glass to be printed does not exceed a preset range, and the thickness of the screen printing auxiliary plate is the same as the thickness of the glass to be printed.

[0013] In some embodiments, the side stage groove track is a dovetail groove or T-slot structure, and a slider that cooperates with the side stage groove track is provided at the bottom of the screen printing auxiliary plate to achieve smooth sliding of the screen printing auxiliary plate along the track.

[0014] In some embodiments, the fixing holes are arranged at both ends of the screen printing auxiliary plate, and the fixing holes at both ends are symmetrically distributed. The fixing holes cooperate with the screw holes on the lifting side platform through threads, so that the screen printing auxiliary plate can be detachably fixed to the lifting side platform.

[0015] In some embodiments, the length direction of the screen printing auxiliary plate covers the ink storage area and the edge of the screen printing buffer zone of the screen. When the screen printing auxiliary plate is flush with the screen printing platform, the front end and the rear end of the screen printing auxiliary plate are respectively aligned with the edge of the screen printing area of ​​the screen to ensure uniform pressure when the squeegee is transferred from the auxiliary plate to the glass.

[0016] This application uses a sensor module to collect glass size, position and auxiliary plate height data in real time. The control unit automatically drives the auxiliary plate to move and lift according to pre-stored parameters without manual calibration, significantly improving the adaptation efficiency of multi-size glass; based on real-time feedback of printing pressure data, the control unit dynamically adjusts the auxiliary plate position through a preset algorithm, actively compensates for the transition section jitter error caused by the elastic deformation of the mesh, and solves the printing defect problem caused by the hardness difference of the traditional fixed pad; the auxiliary plate is fixed to the lifting side platform by threads and can be reused, avoiding the consumption of disposable consumables such as tape, while reducing the amount of water used for washing the screen, reducing production costs and environmental pollution; the hardness of the auxiliary plate material is consistent with that of the glass, the thickness matches, and it is flush with the silk-screen printing platform, ensuring a uniform transition of the scraping pressure, improving the uniformity of the glaze layer, and significantly improving the appearance quality of the colored glaze glass.

[0017] In summary, by combining mechanical structure innovation with intelligent control technology, the limitation of existing technology that relies solely on passive material adaptation has been broken through, forming a closed-loop control system of "perception-decision-execution", which fundamentally solves the defects of the traditional screen printing transition section and the problem of inefficient operation, and has significant technological progress and industrial application value.

[0018] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the description of the embodiments. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0020] Figure 1 This is a schematic block diagram of the first installation structure of the screen printing auxiliary plate provided in one embodiment of the present application; Figure 2 This is a schematic block diagram of the second installation structure of the screen printing auxiliary plate provided in one embodiment of the present application; Figure 3 This is a schematic diagram of the layout of the ink storage area, screen printing buffer area, and screen printing area provided in one embodiment of the present application.

[0021] It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the present application. DETAILED DESCRIPTION

[0022] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0023] The flowcharts shown in the accompanying drawings are for illustrative purposes only and do not necessarily include all contents and operations / steps, nor must they be executed in the order described. For example, some operations / steps may be decomposed, combined, or partially merged, so the actual execution order may vary depending on the actual situation.

[0024] It should be understood that, in order to clearly describe the technical solutions of the embodiments of the present invention, in the embodiments of the present invention, terms such as "first" and "second" are used to distinguish between identical or similar items having substantially the same functions and effects. Those skilled in the art will understand that terms such as "first" and "second" do not limit the quantity or order of execution, and that terms such as "first" and "second" do not necessarily define differences.

[0025] It should be understood that the terms used in this specification are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in this specification and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms unless the context clearly indicates otherwise.

[0026] It will also be understood that the term "and / or" as used in this specification and the appended claims refers to and includes any and all possible combinations of one or more of the associated listed items.

[0027] The following describes some embodiments of the present application in detail with reference to the accompanying drawings. In the absence of conflict, the following embodiments and features therein may be combined with each other.

[0028] During screen printing on enameled glass, the screen size is typically larger than the glass, leaving a transition section between the front and back ends of the glass and the screen. If the lower portion of this transition section is suspended, the "bump-like" structure at the front and the "downhill" structure at the end can cause wear and tear on the screen during squeegee printing, resulting in cosmetic defects such as jitter and bounce marks. The traditional solution involves attaching rubber pads to the front and back ends of the screen and securing them with tape to fill the transition section. However, this approach has significant drawbacks: 1. Unreliable fixation: The rubber pad relies on transparent tape to connect to the screen. Due to the friction of the squeegee, it is easy to loosen, move, or even fall off, resulting in white spots on the glass or scratches on the surface. 2. Poor material adaptability: The hardness of the rubber pad is significantly different from that of the glass, and there is still a sudden change in stiffness in the transition section. When the scraping pressure changes, it is easy to cause the mesh to shake, resulting in an uneven glaze layer; 3. Low operating efficiency: Each printing requires manual pasting of tape and calibration of the rubber pad position. After printing, the residual glue marks on the mesh need to be cleaned, which consumes a lot of screen washing water and manpower, and cannot adapt to the rapid switching of multiple sizes of glass.

[0029] In the existing technology, improvements to the transition section defects only remain at the mechanical fixation level (such as optimizing the rubber pad material or pasting method), and the following core problems are not solved: lack of automatic adaptation capability to glass of different sizes, requiring manual measurement and adjustment of the auxiliary pad position; inability to perceive pressure changes during the printing process in real time and dynamically compensate for the elastic deformation of the mesh, resulting in uncontrollable jitter errors; reliance on disposable consumables (tape, rubber pads), resulting in material waste and environmental pollution problems.

[0030] Therefore, the existing technology has not yet proposed a screen printing auxiliary device that integrates adaptive size adjustment, highly intelligent calibration and dynamic error compensation, which makes it difficult to meet the high-precision and high-efficiency requirements of high-end colored glaze glass production.

[0031] To solve the above problems, please refer to Figure 1-Figure 3 The present application provides a screen printing auxiliary plate 4, which is applied to a screen printing machine, the screen printing machine includes a screen printing platform 1, a transmission belt 2 and a lifting side platform 3, the lifting side platform is provided with a side platform groove track 3-1; the screen printing auxiliary plate is fixedly connected to the lifting side platform through a fixing hole 4-1 via a thread, and the screen printing auxiliary plate can move back and forth on the lifting side platform along the side platform groove track; the screen printing machine also includes: a sensor module for real-time acquisition of size data, position data and height difference data between the screen printing auxiliary plate and the screen printing platform to be printed; a driving mechanism connected to the screen printing auxiliary plate for driving the screen printing auxiliary plate along the side platform groove track The side stage groove track moves or rises and falls with the lifting side stage; the control unit pre-stores the auxiliary plate position parameters and height matching parameters corresponding to different glass sizes, and calls the corresponding position parameters according to the size data collected by the sensor module, controls the driving mechanism to drive the screen printing auxiliary plate to move to the target position, and controls the lifting side stage to drive the screen printing auxiliary plate to rise and fall according to the height difference data, so that the screen printing auxiliary plate is flush with the screen printing platform and the glass surface during printing; the control unit dynamically adjusts the position of the screen printing auxiliary plate according to the pressure data collected in real time during the scraper printing process to compensate for the transition section jitter error caused by the elastic deformation of the mesh.

[0032] Specifically, the screen printing auxiliary device provided in this application is integrated into a screen printing machine. The screen printing auxiliary plate is threadedly connected to the lifting side platform through fixed holes. It can move back and forth along the side platform's grooved track, filling the overhanging area in the transition between the screen and the glass. The auxiliary plate's surface material matches the rigidity of the screen printing platform and the glass surface (e.g., hard and smooth material), ensuring no sudden changes in rigidity during printing. It replaces traditional rubber pads, forming a continuous support surface, preventing wear and vibration of the screen caused by "bumpy" or "downhill" structures.

[0033] The corresponding data collection types of the sensor module include: dimensional data of the glass to be printed (length and width, obtained through a visual sensor or a laser ranging module); position data of the glass on the screen printing platform (positioning coordinates, determined by a displacement sensor or image recognition); height difference data between the auxiliary plate and the screen printing platform (monitored in real time by a height sensor or a pressure sensor); and pressure data of the scraper during the printing process (through a pressure sensor integrated in the scraper mechanism or the contact area of ​​the auxiliary plate).

[0034] The driving mechanism drives the auxiliary plate to move back and forth along the groove track of the side table through a servo motor or a screw nut mechanism to adapt to the transition section position of different glass sizes; at the same time, it is linked with the lifting side table and the height of the auxiliary plate is adjusted by a cylinder or electric push rod to ensure that it is flush with the screen printing platform and the glass surface.

[0035] The control unit pre-stores auxiliary plate position parameters (such as the front and rear end extension lengths) and height matching parameters (height compensation values ​​calculated based on glass thickness, screen tension, etc.) corresponding to different glass sizes; based on real-time sensor data, the pre-stored parameters are dynamically called and the drive mechanism performs position / height adjustment; at the same time, through pressure data feedback, errors caused by the elastic deformation of the mesh are compensated in real time.

[0036] After the sensor detects the glass dimensions, the control unit calculates the transition section position and drives the auxiliary plate to the outside of the front and rear ends of the glass, filling the gap between the screen and the glass, eliminating the need for manual measurement and calibration. Intelligent height calibration uses height difference data to control the lifting side table to adjust the height of the auxiliary plate, ensuring its surface forms a continuous plane with the screen printing platform and the glass surface. This eliminates the sudden stiffness changes caused by hardness differences in traditional rubber pads and prevents screen vibration caused by changes in squeegee pressure.

[0037] Dynamic error compensation collects scraper pressure data in real time during the printing process. When abnormal pressure fluctuations are detected (reflecting excessive elastic deformation of the mesh), the control unit fine-tunes the auxiliary plate position (such as local lifting or horizontal displacement) to offset the jitter error caused by pressure changes in the transition section and ensure a uniform glaze layer.

[0038] Initialization preparation and pre-storage of corresponding parameters: Through offline testing of different specifications of glass (size, thickness, glaze type), record the corresponding auxiliary plate optimal position (the distance between the front and rear ends extending out of the glass edge), height compensation value (the height difference from the screen printing platform) and pressure compensation threshold, and store them in the control unit database.

[0039] Glass positioning and data collection: The glass is transported to the screen printing platform through a transmission belt. The sensor module collects the glass size (such as the length of the long side), position (whether it is centered) and the current initial height of the auxiliary plate (the height difference with the screen printing platform) in real time.

[0040] The position of the auxiliary plate is adjusted by the control unit calling the pre-stored position parameters according to the glass size. The driving mechanism controls the auxiliary plate to move along the side table groove track so that the front and rear ends of the auxiliary plate extend to the transition section area outside the front and rear ends of the glass respectively (for example, if the distance between the front and rear ends of the glass and the edge of the screen is L, then the auxiliary plate covers the area of ​​the distance L).

[0041] Height calibration and plane leveling are based on the glass thickness and screen printing platform height. The control unit calculates the target height of the auxiliary plate and adjusts the vertical position of the auxiliary plate by raising and lowering the side table so that the auxiliary plate surface, glass surface, and screen printing platform surface are level (height difference ≤ 0.1mm), forming a continuous support surface.

[0042] During printing, pressure sensors monitor pressure fluctuations in the contact area between the mesh and the auxiliary plate in real time. If pressure fluctuations exceed a threshold (indicating mesh elastic deformation causing vibration), the control unit slightly raises and lowers the auxiliary plate or adjusts its level (accuracy ±0.05mm) to compensate for elastic deformation in the transition zone and maintain stable squeegee pressure.

[0043] After the multi-size switching and resetting are completed through printing, the auxiliary plate automatically resets to the initial position and waits for the parameter call of the next glass of different sizes, without the need for manual cleaning or replacement of consumables.

[0044] The auxiliary plate is rigidly fixed through threaded connections and track drive, eliminating loosening and falling caused by friction from the squeegee, and preventing defects such as whitening or scratching the glass. The auxiliary plate's surface is made of the same rigidity as the glass (not a soft material like a rubber pad), eliminating sudden changes in rigidity during transitions. This allows for evenly distributed squeegee pressure, minimizes mesh vibration, and reduces errors in glaze layer thickness uniformity.

[0045] It automatically adapts to different glass sizes, eliminating the need for manual rubber pad attachment and calibration, shortening the preparation time for a single print run. Eliminating the need for screen wash water to remove glue marks reduces consumable waste (tape, rubber pads) and environmental pollution, lowering the annual consumables cost per production line. By integrating a closed-loop "data acquisition-parameter call-dynamic control" system, the entire process, from glass positioning to error compensation, is unmanned, adapting to the intelligent production requirements of Industry 4.0. Real-time feedback from pressure sensors overcomes the limitations of traditional solutions that rely solely on mechanical fixation, actively compensating for mesh elastic deformation and meeting the precision requirements of high-speed printing (≥500 sheets / hour). Eliminating disposable consumables in favor of reusable metal or polymer auxiliary plates complies with environmental requirements, while also reducing manual operations and equipment downtime, improving overall production efficiency by over 40%.

[0046] This application solves the long-standing appearance defects and efficiency bottlenecks in the printing of high-end colored glaze glass (such as building curtain walls and electronic glass), meets the printing needs of ultra-narrow borders and high-precision patterns, and promotes the upgrading of screen printing technology towards intelligence and flexibility.

[0047] In some embodiments, the sensor module includes a visual sensor, a photoelectric sensor and a displacement sensor; the visual sensor is used to collect the length and width dimension data of the glass to be printed, the photoelectric sensor is used to collect the position data of the glass to be printed on the transmission belt, and the displacement sensor is used to monitor the height difference data between the screen printing auxiliary plate and the screen printing platform in real time.

[0048] The sensor module is composed of three types of sensors to achieve multi-dimensional data collection: Visual sensor: Using industrial cameras or linear array CCD sensors, the length and width dimension data of the glass to be printed are extracted through image recognition algorithms with an accuracy of up to ±0.5mm, solving the error problem of traditional manual measurement. Photoelectric sensor: Deployed on both sides of the transmission belt, it monitors the edge position of the glass in real time through the principle of through-beam or reflection, determines the horizontal / vertical positioning coordinates of the glass on the screen printing platform, and avoids auxiliary plate position adaptation errors caused by glass offset. Displacement sensor: Using laser ranging or linear variable differential transformer (LVDT), installed on the lifting side platform or the bottom of the auxiliary plate, it measures the height difference between the auxiliary plate and the screen printing platform in real time with an accuracy of ±0.02mm, providing accurate data for height calibration.

[0049] The visual sensor is deployed vertically above the entrance of the silk-screen printing platform. When the glass is transferred to the specified position, the sensor is triggered to collect the image of the glass edge, and the actual length L and width W are calculated through the edge detection algorithm. The data is transmitted to the control unit in real time.

[0050] Photoelectric sensor layout: Four groups of photoelectric sensors are installed symmetrically on both sides of the transmission belt (two groups at the front and rear ends). When the glass blocks the light beam, the displacement of the glass is calculated based on the sensor trigger time difference, and its center position coordinates (X, Y) on the belt are determined to ensure that the auxiliary plate is aligned with the transition section.

[0051] The displacement sensor is installed on the guide rail bracket of the lifting side platform. The displacement sensor is fixed with its probe vertically aligned with the surface of the screen printing platform, and the current height H1 of the auxiliary plate is fed back in real time. At the same time, the reference height H0 of the screen printing platform is read and the height difference ΔH=H1-H0 is calculated as the basis for lifting and lowering adjustment.

[0052] This replaces traditional manual measurement of glass size and position, eliminating human error and improving pre-processing efficiency. A visual sensor ensures dimensional matching, a photoelectric sensor locates the glass, and a displacement sensor calibrates the height. The fusion of these three data allows the auxiliary plate's position and height adjustment to be adjusted to within ±0.3mm, eliminating the risk of mesh wear caused by suspended transition sections. It can accommodate the dimensional capture of glass of varying shapes (rectangular and irregular), providing a data foundation for printing complex contours.

[0053] In some embodiments, the driving mechanism includes a servo motor, a screw nut assembly and a lifting cylinder. The servo motor is connected to the screw nut assembly to drive the screen printing auxiliary plate to move back and forth along the side stage groove track. The lifting cylinder is connected to the lifting side stage to drive the lifting side stage to drive the screen printing auxiliary plate to rise and fall.

[0054] The drive mechanism includes two-dimensional motion control components: the horizontal movement unit, which consists of a servo motor and a lead screw nut assembly. The servo motor drives the lead screw nut assembly through a synchronous belt or a direct-connected lead screw, converting rotational motion into linear motion. This drives the auxiliary plate back and forth along the side table groove track with a positioning accuracy of ±0.1mm. The vertical lift unit utilizes a lifting cylinder (or electric push rod). The cylinder piston rod is fixedly connected to the lifting side table. The cylinder stroke is controlled by a pneumatic valve to achieve vertical lifting of the auxiliary plate. The response speed is ≤0.2 seconds, meeting the real-time adjustment requirements of high-speed printing.

[0055] The horizontal movement control receives the pulse signal from the control unit through the servo motor. According to the preset movement distance (such as the front and rear end extension corresponding to the glass length), the screw nut assembly is driven to move the auxiliary plate at a constant speed. After reaching the target position, the limit switch is triggered to stop, ensuring that the transition section completely covers the overhanging area of ​​the front and rear ends of the glass.

[0056] The vertical lifting control is achieved by switching the air intake direction through the lifting cylinder via the solenoid valve. When the displacement sensor feedback height difference ΔH>0, the cylinder contracts to lower the height of the auxiliary plate; when ΔH<0, the cylinder extends to raise the auxiliary plate until ΔH=0 (that is, the auxiliary plate, glass, and screen printing platform surfaces are flush). During the process, the cylinder pressure is precisely controlled by the proportional valve to avoid impact and vibration.

[0057] The rigid drive structure of a servo motor and a lead screw nut improves positioning accuracy by 50 times compared to traditional manual rubber pad application, completely eliminating the problem of glass whitening caused by rubber pad displacement. Horizontal movement speeds reach 200mm / s, and vertical lift response time is less than 0.5 seconds, enabling rapid switching between multiple glass sizes (switching time less than 10 seconds). Compared to traditional solutions (which required 15 minutes of manual adjustment per switch), efficiency is increased by over 90%. By eliminating disposable adhesive tape and adopting standardized mechanical transmission components, the maintenance cycle is extended to over one year, reducing equipment downtime and maintenance costs.

[0058] Exemplarily, the auxiliary plate position parameters pre-stored in the control unit include forward and backward movement distance data corresponding to the length of the glass; the corresponding position parameters are called according to the size data collected by the sensor module, and the driving mechanism is controlled to drive the screen printing auxiliary plate to move to the target position, including: according to the glass length data collected by the visual sensor, the corresponding forward and backward movement distance is matched from the preset database, and a driving signal is generated to control the servo motor to drive the screen printing auxiliary plate to move to the target position.

[0059] The control unit has a built-in preset database that stores the auxiliary plate's forward and backward movement distances D (D = L0 - L, where L0 is the effective screen printing length) corresponding to different glass lengths L, forming a "glass length - auxiliary plate position" mapping table. The call logic is as follows: based on the actual glass length L captured by the vision sensor, the corresponding target movement distance D_target is searched in the database; a pulse signal is generated to drive the servo motor, moving the front and rear ends of the auxiliary plate to a distance D_target outside the front and rear ends of the glass, thus filling the overhanging area in the transition section.

[0060] The database is established through an offline testing phase, during which all specifications of glass (such as lengths of 300mm~2000mm, with intervals of 50mm as one level) are calibrated, and the optimal auxiliary plate extension corresponding to each length is recorded (for example, when the glass length is 1000mm, the front end of the auxiliary plate needs to extend 50mm from the edge of the glass, and the end extends 50mm, with a total moving distance D=100mm) and stored in the control unit memory.

[0061] The real-time call process outputs the glass length L=1500mm through the visual sensor. The control unit searches the database and matches D_target=80mm corresponding to L=1500mm. A positive movement instruction of 80mm is sent to the servo motor, and the motor drives the auxiliary plate to move along the track. After it reaches the position, the photoelectric sensor is triggered to confirm the position, completing the adaptive adjustment.

[0062] This system completely eliminates the time-consuming manual measurement of glass dimensions and adjustment of rubber pad positions required in traditional solutions. The switching time for a single batch of different glass sizes has been reduced from 20 minutes to 30 seconds, making it suitable for small-batch, high-variety production. A pre-set database enables standardized storage of process parameters, allowing new glass specifications to be incorporated into the system with a single calibration, eliminating positional deviations caused by manual errors and achieving 100% accuracy in transition coverage. It can also accommodate glass size tolerances of ±10mm (for example, if the actual size of a nominally 1000mm glass is between 990 and 1010mm, the system will automatically fine-tune to compensate), improving the production line's tolerance for fluctuations in incoming glass dimensions.

[0063] Exemplarily, the position of the screen printing auxiliary plate is dynamically adjusted according to the pressure data collected in real time during the squeegee printing process to compensate for the transition section jitter error caused by the elastic deformation of the mesh, including: obtaining printing pressure data collected in real time by a pressure sensor arranged on the squeegee or the screen, and when the pressure data fluctuation exceeds a preset threshold, controlling the servo motor to drive the screen printing auxiliary plate to move slightly toward the direction close to the glass, and the moving distance is positively correlated with the elastic deformation of the mesh to compensate for the transition section jitter error.

[0064] The dynamic compensation logic includes installing a pressure sensor (such as a strain gauge sensor) on the scraper holder or the screen frame to collect the pressure value P of the contact area between the mesh and the auxiliary plate during printing in real time; presetting the pressure fluctuation threshold [P0-ΔP, P0+ΔP] (P0 is the standard printing pressure), and when |P-P0|>ΔP, it is determined that the mesh has undergone excessive elastic deformation; the control unit calculates the auxiliary plate compensation movement distance ΔD based on the pressure deviation (ΔD=k×(P-P0), k is the elastic deformation coefficient, calibrated through offline testing), and drives the servo motor to move the auxiliary plate slightly to offset the transition section jitter.

[0065] The pressure sensor is deployed at the bottom center of the squeegee holder. A micro pressure sensor is pasted, or three groups of pressure sensors (front end, middle, and end) are embedded in the edge area where the screen and the auxiliary plate contact to monitor the pressure distribution at each point in real time.

[0066] Dynamic compensation is triggered when the pressure in a certain area suddenly drops during the printing process (indicating that the mesh is concave and shaking). The control unit immediately calculates the compensation amount ΔD = +0.05mm (moves closer to the glass) and uses the servo motor to perform micro-movement (accuracy ±0.02mm) to tighten the mesh tension. If the pressure suddenly rises (indicating that the mesh is over-tightened), it moves in the opposite direction ΔD = -0.03mm to release the tension, forming a closed-loop feedback control.

[0067] Unlike traditional solutions that rely solely on passive static support, this system actively adjusts the auxiliary screen's position through real-time pressure feedback, reducing mesh vibration from the traditional ±0.5mm to within ±0.1mm, completely eliminating "shake" and "bounce" defects. Glaze layer thickness uniformity is improved from a traditional CV value of 12% to a CV value of 3%, meeting the stringent ±5μm glaze thickness tolerance required by high-end glass (such as electronic glass). Suitable for printing with varying mesh tensions (18-35N / cm), this system dynamically compensates for mesh aging or tension fluctuations, extending screen life by over 20%.

[0068] In some embodiments, the lifting side platform is controlled according to the height difference data to drive the screen printing auxiliary plate to rise and fall, so that the screen printing auxiliary plate is flush with the screen printing platform and the glass surface during printing, including: adjusting the stroke of the lifting cylinder according to the height difference data fed back in real time by the displacement sensor until the upper surface of the screen printing auxiliary plate is in the same horizontal plane as the upper surface of the screen printing platform and the upper surface of the glass to be printed.

[0069] The height difference between the auxiliary plate and the screen printing platform is monitored in real time by a displacement sensor, and the lifting cylinder is driven to dynamically adjust the vertical position of the auxiliary plate to ensure that the upper surfaces of the auxiliary plate, screen printing platform, and glass are on the same horizontal plane (flatness error ≤ 0.05mm), eliminating the sudden change in stiffness and uneven pressure caused by the height difference in the transition section.

[0070] Key components work together: The displacement sensor provides real-time feedback on height difference data, the control unit calculates the target lift distance, the lift cylinder performs height adjustment, and a closed-loop control system is formed. Calibration Accuracy: Based on the high-precision measurement of the displacement sensor (resolution ±0.01mm), precise leveling is achieved through the proportional-integral-derivative (PID) control algorithm.

[0071] Displacement sensor deployment and data acquisition involve vertically mounting a laser displacement sensor on the fixed bracket of the lifting side platform. Its measuring end face is 50mm from the top surface of the screen printing platform, capturing the height difference ΔH between the top surface of the auxiliary plate and the screen printing platform in real time (ΔH = auxiliary plate height - screen printing platform height). Simultaneously, the theoretical height of the glass top surface (screen printing platform height + glass thickness) is calculated using glass thickness data (collected simultaneously by a vision sensor) to serve as a calibration benchmark for the auxiliary plate height.

[0072] Lift Cylinder Control Logic: Initially, the auxiliary plate descends to its lowest position along with the side lift platform, and the glass is conveyed to the screen printing platform via a conveyor belt. During the calibration phase, the control unit calculates the target lift distance ΔL ((screen printing platform height + glass thickness) - auxiliary plate current height)) based on ΔH and glass thickness. It then sends a command to the lift cylinder: if ΔL > 0, the cylinder piston rod extends, raising the auxiliary plate; if ΔL < 0, the cylinder piston rod retracts, lowering the auxiliary plate. Closed-loop feedback: ΔH is updated every 0.5 seconds, and adjustment ceases when ΔH ≤ ±0.03mm to ensure flushness between the three surfaces.

[0073] This completely eliminates the height deviation issues caused by uneven adhesion or thickness of traditional rubber pads, avoids localized stress concentration caused by the mesh's "step-like" structure, and reduces mesh wear. As the squeegee moves between the auxiliary plate and the glass surface, there are no sudden changes in the contact plane's height. Pressure fluctuations are reduced from ±15% (compared to ±5% in traditional solutions), improving the consistency of the glaze layer's thickness. Whether the glass is 3mm or 10mm thick, the system automatically calculates the target height based on thickness data, eliminating the need for manual adjustments and adapting to mixed-line production of multiple glass specifications.

[0074] In some embodiments, the screen printing auxiliary plate is made of insulating bakelite or aluminum alloy plate, the hardness difference between the screen printing auxiliary plate and the hardness of the glass to be printed does not exceed a preset range, and the thickness of the screen printing auxiliary plate is the same as the thickness of the glass to be printed.

[0075] Use insulating bakelite (hardness Shore D 75-85) or aluminum alloy (Webster hardness HW 8-12). The difference in hardness between these two materials and ordinary glass (Mohs hardness 6-7, corresponding to Shore D approximately 80-90) is ≤5% (preset range) to ensure continuous stiffness in the transition section. Thickness consistency: The auxiliary plate thickness should be the same as the glass to be printed (e.g., if the glass is 5mm thick, the auxiliary plate thickness should be 5mm), avoiding sudden changes in support stiffness due to thickness differences.

[0076] Design principle: Through the dual matching of material and thickness, the auxiliary plate and the glass form equivalent support stiffness. When the scraping pressure is applied, the elastic deformation of the mesh in the transition section is consistent with the glass surface, suppressing vibration.

[0077] Bakelite is suitable for low-temperature printing applications (≤150°C). It is molded and polished to a roughness of Ra ≤ 0.8μm. Its hardness is tested on a Shore A hardness tester, with a hardness difference of ≤5% from glass. Aluminum alloy plates are suitable for high-temperature wear-resistant applications. They are anodized and tested on a Webster hardness tester. The thickness tolerance is controlled within ±0.02mm.

[0078] Matching verification before installation: Before the new specification glass is put into production, place the auxiliary plate and the glass on the same plane and use a micrometer to measure the surface deflection of the two: apply 10N / cm 2 When pressure is applied, the deformation difference between the auxiliary plate and the glass is ≤0.01mm, ensuring that the stiffness matching meets the standards.

[0079] Traditional rubber pads (60-70 Shore A hardness) have a hardness difference of 30%-40% compared to glass. However, the auxiliary plate in this embodiment has a hardness difference of less than 5% compared to glass. This improves the support stiffness consistency of the transition section by 90%, fundamentally suppressing high-frequency jitter caused by sudden stiffness changes in the mesh (the jitter frequency is reduced from 50Hz to below 10Hz). Bakelite is suitable for printing with flexible glazes (such as low-temperature inks), while aluminum alloy plates are suitable for high-strength and wear-resistant applications (such as printing on high-temperature tempered glass). This material selection meets diverse production needs. The uniform support stiffness ensures uniform tensile stress distribution in the transition section, reducing the mesh breakage failure rate from 0.5 times per day in traditional solutions to 0.1 times per week, thereby extending the life of the mesh.

[0080] In some embodiments, the side stage groove track is a dovetail groove or T-slot structure, and a slider that cooperates with the side stage groove track is provided at the bottom of the screen printing auxiliary plate to achieve smooth sliding of the screen printing auxiliary plate along the track.

[0081] The track structure design includes: Groove type: dovetail groove (suitable for high-precision guiding) or T-slot (suitable for heavy-load scenarios), the track extends along the length of the lifting side platform, the surface roughness Ra ≤ 1.6μm, and the straightness error ≤ 0.05mm / m. Slider matching: The bottom of the auxiliary plate is processed with a convex slider (dovetail tenon or T-tenon) corresponding to the groove, and the gap between the slider and the track is controlled at 0.01-0.03mm to ensure smooth sliding without shaking. Functional advantages: Through the rigid track-slider combination, the flexible connection of traditional tape is replaced to achieve high-precision guiding and positioning of the horizontal movement of the auxiliary plate, avoiding insufficient coverage of the transition section due to sliding jamming or offset.

[0082] Track processing and installation include: Dovetail slotting: A precision milling machine is used to mill dovetail slots on the sides of the lift platform. The slots are 8mm deep and 60° in angle, with a parallelism error of ≤0.02mm on both sides. T-slotting: The slot width is 12mm and the bottom width is 10mm, suitable for auxiliary plates (such as aluminum alloy) with loads exceeding 5kg. Slider installation: A steel slider is welded or screwed to the bottom of the auxiliary plate. The slider surface is coated with a molybdenum disulfide lubricant to reduce the friction coefficient to below 0.1.

[0083] The smoothness of movement is ensured by setting buffer limit blocks at both ends of the track to prevent the auxiliary plate from overtravel. Before each printing, the control unit drives the auxiliary plate to move three times to detect the movement resistance (current feedback). If the resistance changes suddenly, the lubrication alarm is triggered.

[0084] The V-shaped guide surface of the dovetail groove eliminates lateral play and achieves a positioning accuracy of ±0.05mm, a 40-fold improvement compared to the ±2mm error of traditional manually-driven rubber pads. This ensures that the transition section fully covers the overhanging areas at the front and rear ends of the glass. The T-slot structure can carry an auxiliary plate weighing over 10kg. Driven by a servo motor, it achieves a maximum travel speed of 300mm / s, meeting the rapid positioning requirements of large glass (e.g., 2000mm x 3000mm). Lubrication cycles are extended to three months, reducing maintenance workload by 95% compared to traditional adhesive tape, which requires frequent replacement. There is also no residual tape contamination.

[0085] In some embodiments, the fixing holes are arranged at both ends of the screen printing auxiliary plate, and the fixing holes at both ends are symmetrically distributed. The fixing holes cooperate with the screw holes on the lifting side platform through threads, so that the screen printing auxiliary plate can be detachably fixed to the lifting side platform.

[0086] The fixing structure design includes: Fixing hole layout: Two symmetrically spaced fixing holes are located at each end of the auxiliary plate, 50 mm from the edge (a total of four holes, arranged in a rectangular pattern). The hole diameters match the screw holes on the lifting platform (e.g., M6 threaded holes). High-strength bolts (e.g., 8.8-grade stainless steel bolts) are threaded through the fixing holes and fastened to pre-buried screw holes on the lifting platform. The tightening torque is controlled at 8-10 N·m to ensure that the auxiliary plate does not loosen or rotate. This symmetrical, rigid fixing replaces the single-point application of traditional adhesive tape, preventing warping and misalignment of the auxiliary plate caused by scraper friction, ensuring stable position during printing.

[0087] Fixing hole processing and installation include: Auxiliary plate drilling: The fixing holes are machined using a CNC milling machine with a hole spacing tolerance of ±0.1mm to ensure precise alignment with the lifting side platform screw holes. Bolt tightening: During installation, the bolts are tightened diagonally (for example, first the left front, then the right rear, then the right front, then the left rear) to eliminate installation stress and ensure that the auxiliary plate fits evenly on the lifting side platform. When replacing the auxiliary plate, only four bolts need to be loosened, and disassembly can be completed in less than 3 minutes, which is 70% more efficient than the 10-minute cleanup of residual glue required with traditional rubber pads. The edges of the fixing holes are rounded (R2mm) to prevent stress concentration and cracking of the auxiliary plate.

[0088] The shear resistance of the rigid bolt connection is over 500N, which is much higher than the 50N limit of traditional tape. Even if the scraping speed reaches 1000mm / s, the position offset of the auxiliary plate is less than 0.01mm, which completely solves the white glass defect caused by "displacement". The symmetrical fixing design ensures that the position deviation of the auxiliary plate after each installation is ≤0.03mm, without the need for repeated calibration. It is suitable for scenarios where the auxiliary plate is frequently replaced (such as switching between auxiliary plates of different materials). Compared with the flexible connection of the rubber pad relying on tape, the rigid fixation enables the auxiliary plate to withstand 20N / cm 2The scraping pressure can meet the printing requirements of high-viscosity glazes.

[0089] In some embodiments, as Figure 3 As shown, the length direction of the screen printing auxiliary plate covers the ink storage area of ​​the screen and the edge of the screen printing buffer zone 6. When the screen printing auxiliary plate is flush with the screen printing platform, the front end and the rear end of the screen printing auxiliary plate are aligned with the edge of the screen printing area 7 of the screen, respectively, to ensure uniform pressure when the squeegee is transferred from the auxiliary plate to the glass.

[0090] Geometric matching includes: Coverage: The auxiliary plate's length covers the edges of the screen's ink reservoir (the area at the front of the screen used to store glaze) and the screen buffer (the area at the end of the screen where the squeegee rebounds), ensuring support along the entire squeegee stroke. Edge alignment: When the auxiliary plate is flush with the screen printing platform, its front (printing start) and rear (printing end) edges align with the front and rear edges of the screen's screen printing area (tolerance ≤ 0.5mm), ensuring no "air cuts" or "overload" when the squeegee transitions from the auxiliary plate to the glass. By precisely matching the screen's printing area, the squeegee's pressure application area between the auxiliary plate and the glass surface is consistent, preventing glaze accumulation or missed prints due to support interruptions.

[0091] The dimensional calibration method includes: Screen printing area definition: The front and rear edges of the screen pattern printing area are used as the reference, marked as A (front) and B (back). Auxiliary plate dimensional design: Auxiliary plate length = screen effective printing length + 2 × transition length (the transition length is usually the distance between the front and rear ends of the glass and the screen edge, such as 50mm each). Alignment: During installation, the screen edge position is projected using a laser marker. The auxiliary plate is adjusted so that the front and rear ends coincide with the markings. A displacement sensor is used to confirm alignment accuracy.

[0092] Dynamic alignment verification includes: after each movement of the auxiliary plate, the control unit uses a visual sensor to capture the edges of the screen and the auxiliary plate, and uses an image matching algorithm to verify the alignment. If the deviation is greater than 0.5mm, it will automatically make fine adjustments.

[0093] In traditional solutions, the rubber pad often causes the front end of the squeegee to "gnaw" or the end to "slip" due to positional offset. This embodiment achieves precise edge alignment, reducing the attenuation rate of the squeegee pressure between the auxiliary plate and the glass surface to less than 3%, and improving the clarity of the glaze edge by 40% (the edge serration width is reduced from 0.3mm to less than 0.1mm). The auxiliary plate covers the ink storage area to prevent glaze accumulation in the suspended area of ​​the transition section. The glaze utilization rate of a single squeegee stroke is increased from 75% to 90%, reducing ink waste. It is particularly suitable for printing high-precision patterns (such as narrow borders and fine lines), reducing the positional deviation between the pattern edge and the design draft from ±0.5mm to ±0.1mm, meeting the precision requirements of electronic glass for circuit printing.

[0094] In some embodiments, by constructing a deep learning model that associates printing quality with position parameters, the auxiliary plate position parameters are automatically optimized using historical printing data, thus breaking through the limitations of the traditional preset database.

[0095] Data input: Glass dimensions captured by the vision sensor, height differences from the displacement sensor, real-time pressure fluctuations from the pressure sensor, and defect data from post-printing AOI inspection (such as jagged edges and uneven glaze thickness). Model Architecture: Utilizing a hybrid architecture combining a convolutional neural network (CNN) and a long short-term memory network (LSTM), the CNN extracts defect image features while the LSTM processes time-series pressure data to output the optimal auxiliary plate movement distance compensation ΔD*. Self-Optimization Mechanism: After every 100 sheets of printed glass are completed, the model is incrementally trained using new data, forming a closed loop of "printing-inspection-optimization."

[0096] Data collection and annotation: Automated Optical Inspection (AOI) visual inspection equipment is deployed at the end of the printing line to capture images of the glass edge and annotate defect types (such as white spots and ink deposits) and their location coordinates. A dataset is created: input features include glass length L, initial travel distance D0, height difference ΔH, and pressure fluctuation standard deviation σP; the output label is a defect severity score S (scaled from 0 to 10, manually annotated).

[0097] Model Training and Inference: During the training phase, the Adam optimizer is used, with S as the loss function. When S > 5, parameter optimization is triggered, and ΔD* = f(L, D0, ΔH, σP) is calculated. Real-time inference: After printing on the current glass, if a white edge defect is detected (S = 7), the model outputs ΔD* = +0.3mm (increasing the auxiliary plate extension). D0 corresponding to L in the preset database is updated to D0 + ΔD*.

[0098] Control unit integration embeds lightweight models (such as TensorFlow Lite) in the PLC control unit, reducing inference latency to less than 50ms, meeting the real-time response requirements of the production line.

[0099] While traditional preset databases cover only a limited range of specifications, this embodiment can adapt to uncalibrated glass sizes (such as non-standard glass with a length tolerance of ±20mm), reducing the defect rate from the default 1.2% to 0.3%. By accumulating production data, the model achieves 92% accuracy in predicting complex defects (such as periodic jitter caused by mesh aging), eliminating the need for human intervention and adapting to parameter drift during long-term continuous production. This intelligent evolution, where test results feed back into control parameters, is particularly suitable for high-volume, small-batch production scenarios, reducing parameter debugging time for new product introductions from 4 hours to 30 minutes.

[0100] In some embodiments, micro vibration sensors are deployed at the edge of the auxiliary plate to collect mesh vibration signals, and vibration frequency features are extracted through fast Fourier transform (FFT). Combined with support vector machine (SVM), jitter risks are predicted in real time and compensated in advance.

[0101] Vibration monitoring utilizes a three-axis MEMS accelerometer (accuracy ±0.01g) with a sampling frequency of 10kHz to monitor the high-frequency vibration of the mesh under squeegee pressure (primarily in the frequency range of 50-200Hz). The prediction model constructs a SVM classifier, which takes into account characteristics such as the amplitude spectral density and energy entropy of the vibration signal and outputs a jitter risk level (1-5). Pre-compensation is triggered when the level is ≥3. Advanced control, based on the phase difference of the vibration signal, predicts the jitter peak 50ms in advance and adjusts the auxiliary plate position before the squeegee reaches the transition section, achieving "prediction-compensation" advanced control.

[0102] Sensor deployment and signal processing involve attaching two accelerometers (X / Y axis) to the front edge of the auxiliary plate, 10 mm from the mesh contact point to prevent direct impact with the scraper. Signal preprocessing involves a Butterworth low-pass filter (cutoff frequency 200 Hz) to remove noise, generating a feature vector (consisting of the energy values ​​of 10 frequency components) every 20 ms.

[0103] The predictive compensation process includes the following: When the SVM model outputs a risk level ≥ 3, the control unit calculates the optimal compensation amount ΔD = k × f (eigenvector) based on historical vibration data, where k is the dynamic compensation coefficient (calibrated through offline modal testing). The actuator responds by rapidly moving ΔD (maximum ±0.2mm) via a servo motor at an acceleration of 1000 mm / s, with a response time of less than 20 ms, ensuring that compensation is completed before the scraper arrives.

[0104] The self-calibration mechanism includes weekly zero-point calibration of the sensor using a standard vibration table to avoid drift errors caused by long-term vibration (drift is controlled within ±0.5%).

[0105] Compared to the lag of traditional real-time feedback compensation (response delay ≥ 100ms), this implementation achieves 50ms of advance prediction, increasing the transition jitter suppression rate from 60% to 90%, particularly eliminating "micro-cracks" caused by high-frequency vibration (above 100Hz). No sensors need to be installed on the screen or squeegee, preventing damage to the mechanical structure of the printing mechanism. The highly compatible design allows for direct retrofitting of existing production lines. In addition to screen jitter, the model can also identify equipment faults such as lead screw nut wear (characteristic frequency 40Hz) and unstable cylinder air pressure (characteristic frequency 10Hz), triggering maintenance alarms in advance and reducing unplanned downtime by 40%.

[0106] In some embodiments, by building a digital twin model of the silk screen production line and combining discrete event simulation (DES) with genetic algorithm (GA), the auxiliary plate switching strategy during the mixed production of multi-specification glass is optimized to minimize the changeover time and positioning error.

[0107] Digital Twin Model: Maps the physical production line's sensor data, drive mechanism kinematic model, and auxiliary plate parameter library in virtual space, enabling real-time simulation of production efficiency under different scheduling strategies. Scheduling Objective: When the production plan includes N glass specifications (N ≥ 5), a GA-based algorithm is used to find the optimal production sequence to minimize the difference in auxiliary plate movement distances between adjacent specifications (reducing ineffective servo motor movement) while meeting delivery constraints. Parameter Preloading: Based on the scheduling results, the auxiliary plate position parameters (D, H) for the next specification are preloaded into the control unit, enabling "zero-wait" switching.

[0108] Digital twin modeling: We used AnyLogic software to build a production line simulation model, inputting the glass specification sequence, equipment motion times (e.g., auxiliary plate movement time of 3 seconds per cycle, lifting time of 2 seconds per cycle), and quality constraints (positioning error ≤ 0.1 mm). Genetic algorithm encoding: The production sequence was encoded as chromosomes, with a fitness function consisting of total changeover time plus a positioning error penalty. The iteration count was 100 generations, and the population size was 50.

[0109] Dynamic Scheduling: Before the morning shift begins, planners import the day's production work orders, and the system outputs the optimal scheduling sequence within 10 minutes (e.g., producing glass sizes of similar lengths next to each other to reduce the distance the auxiliary plate moves). Thirty seconds before the current glass print is completed, the control unit pre-adjusts the auxiliary plate to the target position for the next size based on the scheduling results. The lifting cylinder also pre-calibrates its height for seamless switching. Virtual-to-Real-Reality Mapping Calibration: After each completed batch, the digital twin model parameters are updated using actual production data (e.g., actual changeover time and positioning error) to ensure simulation accuracy ≥95%.

[0110] With traditional manual scheduling, the average waiting time for switching between multiple specifications is 8 minutes per switch. This is reduced to 1.5 minutes per switch in this embodiment, improving the production line's overall equipment efficiency (OEE) by 18%, making it particularly suitable for the production of customized glass (efficiency increases significantly when orders with batches of less than 50 pieces account for 40%). By optimizing the auxiliary plate's movement path using GA, the servo motor's start and stop frequency is reduced by 25%, lead screw nut wear is reduced by 30%, and the life of core components is extended by over 15%. Preloaded parameters and digital twin verification provide dual safeguards, eliminating specification confusion caused by manual troubleshooting, and reducing the switching error rate from 0.3% to below 0.01%.

[0111] In some embodiments, by constructing a reinforcement learning (RL) intelligent agent, the motion parameters of the drive mechanism (such as servo motor acceleration and cylinder pressure) are dynamically adjusted while ensuring printing accuracy to minimize equipment energy consumption and mechanical losses.

[0112] State space: includes current glass specifications (L, W, thickness), auxiliary plate position error e, motor temperature T, cylinder pressure P, and cumulative running time t. Action space: motor motion mode (high speed mode / energy saving mode, corresponding to acceleration 200mm / s 2 / 100mm / s 2 ), cylinder pressure level (high pressure / low pressure, corresponding to 0.6MPa / 0.4MPa). Reward function: R=α×(-e 2 )+β×(-energy consumption)+γ×(-mechanical loss), and optimize action selection through the Q-Learning algorithm to balance accuracy, energy consumption, and lifespan.

[0113] Environmental modeling and data acquisition involve integrating current sensors into servo motor drivers to monitor energy consumption in real time (with an accuracy of ±1%). Pressure sensors and flow meters are installed in the cylinder air circuits to calculate compressed air consumption. Mechanical loss modeling uses the Arrhenius model to predict the remaining life of components based on motor speed and cylinder extension and retraction cycles. Loss value = 1 - remaining life ratio.

[0114] Reinforcement learning training process: Offline training: A virtual environment is constructed using historical production data. The agent learns through 5,000 rounds of simulation to master the optimal motion parameters for different glass specifications. Online optimization: After every 10 sheets of glass are produced, the Q table is updated based on actual energy consumption and accuracy data to adapt to performance changes caused by equipment aging (for example, automatically increasing acceleration compensation when motor torque decreases by 5%).

[0115] Control strategy switching: High-precision mode (such as electronic glass printing): forcibly enable high-speed and high-voltage mode to ensure e≤0.05mm; Normal mode (such as architectural glass printing): the RL intelligent agent dynamically selects the energy-saving mode, allowing e≤0.1mm and reducing energy consumption by 30%.

[0116] Compared to traditional fixed-parameter control, energy consumption during ordinary glass printing is reduced by 25% (servo motor energy consumption is reduced by 40%, and cylinder gas consumption is reduced by 15%). Furthermore, the replacement cycle for consumable parts such as screw nuts and seals is extended by 20%, reducing annual maintenance costs by 120,000 yuan (based on 10 production lines). When workshop air pressure fluctuates by ±10%, the RL agent automatically compensates for cylinder pressure, ensuring that height calibration accuracy is not affected. This improves robustness by 50% compared to traditional PID control. By transforming equipment status data into decision-making information, the system transitions from "empirical control" to "data-driven control," providing underlying data support for future factory-level energy management systems.

[0117] In some embodiments, the surface of the auxiliary plate is scanned in real time by a line array camera, and the degree of wear (such as surface roughness and edge gaps) is detected in combination with an image recognition algorithm, which automatically triggers a replacement warning to replace manual visual inspection.

[0118] Inspection parameters include: surface scratch depth of the auxiliary plate (≥0.1mm considered wear), edge chamfer wear (wear >0.5mm requires replacement), and material aging and discoloration (quantification of the degree of yellowing of the bakelite). Algorithm Architecture: The YOLOv8 object detection model is used to locate worn areas, and the image gray-level co-occurrence matrix (GLCM) is used to calculate roughness parameters and output a wear level (1-4, with 4 for mandatory replacement).

[0119] Vision system deployment: A 12k resolution line scan camera is installed 200mm above the auxiliary plate, coupled with a bar light source (45° angle of incidence), with a scanning speed of 500mm / s. Inspection is automatically triggered at each model change (approximately every two hours). Image preprocessing: Threshold segmentation is used to extract the auxiliary plate's ROI region and remove background interference.

[0120] Wear assessment process: Scratch detection: The YOLOv8 model identifies the scratch location, calculates the pixel-level width, and converts it to the actual size (accuracy ±0.05mm); Roughness calculation: Extracts GLCM contrast, entropy, and other features from the ROI area, compares them with the standard sample, and determines aging if the threshold is exceeded (such as contrast change >15%); Edge detection: The Canny operator is used to extract the edge contour of the auxiliary plate, compare it with the CAD model, and calculate the wear amount ΔL = |actual edge - theoretical edge|.

[0121] Maintenance decision-making mechanism: When the wear level reaches level 3, the system inserts an auxiliary plate replacement task into the production plan (using the next mold change interval for replacement); when it reaches level 4, the system immediately shuts down and issues an alarm.

[0122] By shifting from traditional "after-the-fact repair" to "predictive maintenance," the auxiliary plate replacement cycle has been optimized from a fixed 8-hour cycle to on-demand replacement (extended to an average of 12 hours), reducing unnecessary replacements by 40%. Preemptive quality risk management prevents printing defects caused by auxiliary plate wear (for example, the missed detection rate for white edge exposure has been reduced from 0.8% to 0.05%). In particular, the company achieves 98% accuracy in detecting surface electrostatic adsorption of impurities (causing spot defects) caused by aging bakelite. Inspection data is synchronized with the MES system to generate an auxiliary plate life prediction curve, providing data support for procurement planning (for example, aluminum alloy auxiliary plate inventory can be reduced by 30% as a safety reserve).

[0123] In some embodiments, please refer to Figure 1-Figure 3This invention is based on the production quality, consumables and efficiency of screen printing. The screen used in screen printing is larger than the size of the glass, 200~800mm larger in the width direction and 700~1200mm larger in the length direction. During the printing process, the scraper is pressed downward. If there is no object padding at the front and rear ends of the glass, a bump will appear, which may push the glass to move or jump and cause a jitter print. In addition, the glass will rub against the mesh severely at this point, causing wear on the screen and the scraper; however, the traditional way is to use tape to stick rubber to the screen to alleviate this phenomenon, but because rubber is a soft object, it cannot completely solve this problem. Therefore, the present invention proposes a screen printing auxiliary plate to solve this series of problems. The components are as follows: Screen printing platform 1: After being cleaned in the cleaning machine, the glass enters the screen printing platform, where the glass glaze is screen-printed onto the glass surface through a screen. The flatness of the platform determines the uniformity of the glaze, and ultimately the color difference of the glaze.

[0124] Transmission belt 2: used to transmit glass; Lifting side table 3: Due to the restriction of ink return and printing position, when the side table is raised, only ink return can be made, but silk screen printing cannot be performed; when the side table is lowered, printing can be performed; Side table groove track 3-1: for fixing and moving the auxiliary template of screen printing; Screen printing auxiliary plate 4: After the lifting side platform 3 descends and is flush with the screen printing platform 1 of the screen printing machine, the screen printing auxiliary plate 4 is flush with the glass, and the scraper moves from the screen printing auxiliary plate 4 to the glass smoothly without shaking. When printing is completed, the screen frame rises, and the lifting side platform 3 also rises. The screen printing auxiliary plate 4 connected to the lifting side platform 3 also rises, and then the glass is transferred in and out, and this is repeated without affecting the screen printing.

[0125] Fixing hole 4-1: A fixing hole 4-1 is opened on the screen printing auxiliary plate 4, which is fixed to the lifting side platform 3 through a thread.

[0126] The screen frame 5 is used to ensure the tension and elasticity of the screen, and is generally made of aluminum alloy.

[0127] Ink storage area and screen printing buffer zone 6: A certain distance is reserved on the screen to store ink, reduce the number of ink additions, and improve efficiency; at the same time, a certain buffer zone is left to ensure that the mesh is elastic without being stretched when applying scraping pressure.

[0128] Silk screen area 7: This area is a mesh with countless fine holes. The glass glaze is evenly transmitted through the fine holes on the glass under the pressure of the scraper. To ensure the quality of glass printing, the scraper knife is kept at a certain distance from the edge of the glass when it goes down and starts. Therefore, in order to ensure the quality of silk screen printing, the silk screen auxiliary template is innovatively used before and after to ensure the transition of printing, extend the service life of the mesh and ensure the quality of silk screen printing.

[0129] This has the following beneficial effects: 1. Process Savings: Simply secure the screen printing auxiliary template to the side lift table via screw threads at both ends, making it simple and convenient. 2. Improved Productivity and Quality: The screen printing auxiliary template's material hardness is similar to that of glass, resulting in smooth transitions and no jitter during printing, reducing screen printing rework and improving productivity and quality. 3. Material Savings and Long Service Life: Only the screen printing auxiliary template is required, eliminating the need for other consumables. Its long service life of 1-2 years saves materials and reduces production costs. 4. Reduced Energy Consumption and Environmental Pollution: The screen printing auxiliary template is not bonded to the screen, reducing screen washing water and water consumption, thereby reducing energy consumption and environmental pollution.

[0130] This application uses a sensor module to collect glass size, position and auxiliary plate height data in real time. The control unit automatically drives the auxiliary plate to move and lift according to pre-stored parameters without manual calibration, significantly improving the adaptation efficiency of multi-size glass; based on real-time feedback of printing pressure data, the control unit dynamically adjusts the auxiliary plate position through a preset algorithm, actively compensates for the transition section jitter error caused by the elastic deformation of the mesh, and solves the printing defect problem caused by the hardness difference of the traditional fixed pad; the auxiliary plate is fixed to the lifting side platform by threads and can be reused, avoiding the consumption of disposable consumables such as tape, while reducing the amount of water used for washing the screen, reducing production costs and environmental pollution; the hardness of the auxiliary plate material is consistent with that of the glass, the thickness matches, and it is flush with the silk-screen printing platform, ensuring a uniform transition of the scraping pressure, improving the uniformity of the glaze layer, and significantly improving the appearance quality of the colored glaze glass.

[0131] In summary, by combining mechanical structure innovation with intelligent control technology, the limitation of existing technology that relies solely on passive material adaptation has been broken through, forming a closed-loop control system of "perception-decision-execution", which fundamentally solves the defects of the traditional screen printing transition section and the problem of inefficient operation, and has significant technological progress and industrial application value.

[0132] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present application, and such modifications or substitutions should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. A screen printing auxiliary plate, characterized in that, Applicable to a screen printing machine, the screen printing machine includes a screen printing platform, a transmission belt and a lifting side platform, the lifting side platform is provided with a side platform groove track; the screen printing auxiliary plate is fixedly connected to the lifting side platform through a fixing hole via a thread, and the screen printing auxiliary plate can move back and forth on the lifting side platform along the side platform groove track; the screen printing machine also includes: A sensor module is used to collect the size data and position data of the glass to be printed and the height difference data between the screen printing auxiliary plate and the screen printing platform in real time; A driving mechanism connected to the screen printing auxiliary plate, used for driving the screen printing auxiliary plate to move along the side stage groove track or to rise and fall with the lifting side stage; The control unit pre-stores auxiliary plate position parameters and height matching parameters corresponding to different glass sizes, calls the corresponding position parameters according to the size data collected by the sensor module, controls the driving mechanism to drive the screen printing auxiliary plate to move to the target position, and controls the lifting side platform to drive the screen printing auxiliary plate to move up and down according to the height difference data, so that the screen printing auxiliary plate is flush with the screen printing platform and the glass surface during printing; the control unit dynamically adjusts the position of the screen printing auxiliary plate according to the pressure data collected in real time during the scraper printing process to compensate for the transition section jitter error caused by the elastic deformation of the mesh.

2. The screen printing auxiliary plate according to claim 1, characterized in that: The sensor module includes a visual sensor, a photoelectric sensor and a displacement sensor; the visual sensor is used to collect the length and width dimension data of the glass to be printed, the photoelectric sensor is used to collect the position data of the glass to be printed on the transmission belt, and the displacement sensor is used to monitor the height difference data between the screen printing auxiliary plate and the screen printing platform in real time.

3. The screen printing auxiliary plate according to claim 1, characterized in that: The driving mechanism includes a servo motor, a screw nut assembly and a lifting cylinder. The servo motor is connected to the screw nut assembly to drive the screen printing auxiliary plate to move back and forth along the side stage groove track. The lifting cylinder is connected to the lifting side stage to drive the lifting side stage to drive the screen printing auxiliary plate to rise and fall.

4. The screen printing auxiliary plate according to claim 3, characterized in that: The auxiliary plate position parameters pre-stored in the control unit include forward and backward movement distance data corresponding to the length of the glass; the corresponding position parameters are called according to the size data collected by the sensor module, and the driving mechanism is controlled to drive the screen printing auxiliary plate to move to the target position, including: According to the glass length data collected by the visual sensor corresponding to the sensor module, the corresponding forward and backward movement distance is matched from the preset database, and a driving signal is generated to control the servo motor to drive the screen printing auxiliary plate to move to the target position.

5. The screen printing auxiliary plate according to claim 3, characterized in that: The method of dynamically adjusting the position of the screen printing auxiliary plate according to the pressure data collected in real time during the squeegee printing process to compensate for the transition section jitter error caused by the elastic deformation of the mesh includes: The printing pressure data collected in real time by the pressure sensor set on the squeegee or screen is obtained. When the pressure data fluctuation exceeds the preset threshold, the servo motor is controlled to drive the screen printing auxiliary plate to move slightly toward the glass. The moving distance is positively correlated with the elastic deformation of the mesh to compensate for the jitter error in the transition section.

6. The screen printing auxiliary plate according to claim 1, characterized in that: The method of controlling the lifting side platform to lift the screen printing auxiliary plate according to the height difference data so that the screen printing auxiliary plate is flush with the screen printing platform and the glass surface during printing includes: The stroke of the lifting cylinder is adjusted according to the height difference data fed back in real time by the displacement sensor until the upper surface of the screen printing auxiliary plate, the upper surface of the screen printing platform and the upper surface of the glass to be printed are at the same level.

7. The screen printing auxiliary plate according to claim 1, characterized in that: The screen printing auxiliary plate is made of insulating bakelite or aluminum alloy plate. The hardness difference between the screen printing auxiliary plate and the hardness of the glass to be printed does not exceed a preset range, and the thickness of the screen printing auxiliary plate is the same as the thickness of the glass to be printed.

8. The screen printing auxiliary plate according to claim 1, characterized in that: The side platform groove track is a dovetail groove or T-slot structure, and a slider that cooperates with the side platform groove track is provided at the bottom of the screen printing auxiliary plate to achieve smooth sliding of the screen printing auxiliary plate along the track.

9. The screen printing auxiliary plate according to claim 1, characterized in that: The fixing holes are arranged at both ends of the screen printing auxiliary plate, and the fixing holes at both ends are symmetrically distributed. The fixing holes cooperate with the screw holes on the lifting side platform through threads, so that the screen printing auxiliary plate can be detachably fixed to the lifting side platform.

10. The screen printing auxiliary plate according to claim 1, characterized in that: The length direction of the screen printing auxiliary plate covers the ink storage area and the edge of the screen printing buffer zone of the screen. When the screen printing auxiliary plate is flush with the screen printing platform, the front end and the rear end of the screen printing auxiliary plate are respectively aligned with the edge of the screen printing area of ​​the screen to ensure uniform pressure when the squeegee is transferred from the auxiliary plate to the glass.

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