Emergency treatment system and method for unwinding system for filter tip material production

Abstract

The invention discloses an emergency treatment system and method for an unwinding system for filter tip material production. The emergency treatment system comprises a motor set, a tension roller set, a brake assembly and a control system, and a motor monitor is used for collecting motor current data and motor temperature data; the tension sensor is used for collecting material tension data, and the encoder is used for collecting unwinding roller rotating speed data and / or material conveying speed; the brake assembly is used for emergency shutdown. Compared with traditional emergency processing which depends on manual intervention and has obvious lagging in fault discovery and processing, the method has the advantages that parameters are acquired in real time through a sensor, rapid identification and classification of faults are realized in combination with automatic analysis of a system, and the time cost of manual troubleshooting is saved. No matter whether the tension is adjusted in real time or the material is broken for emergency shutdown, the corresponding processing flow can be started at the moment of failure, the failure response time is effectively shortened, and chain losses such as material waste and equipment damage caused by failure continuity are reduced to the maximum extent.

Description

Technical Field

[0001] This invention belongs to the field of intelligent control of equipment for the production of nozzle materials, and specifically relates to an emergency handling system and method for an unwinding system for the production of nozzle materials. Background Technology

[0002] In the sophisticated chain of modern industrial production, the unwinding system of the filter rod production line is an indispensable core hub. It bears the crucial mission of precisely releasing the rolled raw materials (such as filter rod forming paper) at a preset speed and tension, providing a continuous and stable material supply for subsequent processes such as cutting, splicing, and forming. It can be said that the stability of the unwinding process directly constitutes the first line of defense for product quality—any fluctuation can lead to uneven cigarette rolling tension and misaligned filter rods, or even the scrapping of the entire batch. At the same time, its operational status also profoundly affects production efficiency; any unplanned interruption can cause the production line to stop waiting for materials, disrupting the rhythm of the entire production plan.

[0003] However, in actual production environments, unwinding systems often face interference from multiple complex factors. Regarding material properties, uneven thickness, surface wrinkles, or sudden thickness changes at roll joints in raw materials during production can all cause instantaneous tension fluctuations during unwinding. Equipment wear and tear is also significant; aging drive motors can lead to unstable speed output, zero-point drift or signal transmission failures in tension sensors can cause distorted data, and wear and deformation of guide rollers can cause material misalignment. Furthermore, even minor errors by operators during roll changes and parameter settings can become potential triggers for malfunctions. The combination of these factors can easily lead to sudden malfunctions such as tension spikes, material breakage, and edge misalignment, posing a severe challenge to production continuity.

[0004] The current emergency response mechanisms of unwinding systems are still largely at a rudimentary stage, relying on manual intervention or simple shutdown protection. This is insufficient to meet the high-precision and high-efficiency demands of modern production, and its limitations are mainly reflected in three dimensions: First, there is a significant lag in fault response. Since faults often initially manifest as subtle parameter fluctuations, by the time operators discover abnormalities through visual observation or regular inspections, the optimal handling opportunity has often been missed. The time lag between the occurrence of a fault and manual intervention not only results in the ineffective consumption of a large amount of raw materials but may also cause irreversible damage to core components of the equipment (such as servo motors and transmission gears) due to continuous abnormal tension. Second, the handling methods are too simplistic and rigid. Existing systems lack intelligent judgment capabilities, employing a one-size-fits-all shutdown approach regardless of the fault type or severity. This "better to stop wrong than let wrong" strategy, while preventing the fault from escalating, leads to frequent unplanned shutdowns that severely disrupt the production process, significantly reducing equipment utilization and output. Third, there is a lack of targeted and differentiated handling capabilities. Different types of faults require different response strategies: for example, when tension is slightly abnormal, stability can be restored by adjusting the motor speed or tension controller parameters in real time; however, for serious faults such as material breakage, the machine must be shut down. But existing systems cannot accurately identify the type and severity of faults, often escalating adjustable minor abnormalities directly into shutdown events, causing unnecessary production interruptions.

[0005] Furthermore, unlike the independent unwinding systems in other industries, multiple different unwinding systems in the production of nozzle materials operate simultaneously and collaboratively, increasing the risk of malfunctions affecting the overall operation of the nozzle material production line. Summary of the Invention

[0006] The purpose of this invention is to propose a complete emergency handling method for various unexpected failures that may occur during the operation of the unwinding system used in the production of nozzle rod materials, thereby reducing the exponential increase in the risk factor to the overall production line caused by the interactive and coordinated operation of the unwinding system. To solve this technical problem:

[0007] The first aspect of this invention provides an emergency handling system for an unwinding system used in the production of nozzle materials. The emergency handling system includes: a motor unit, a tension roller group, a braking assembly, and a control system. The motor unit drives the tension roller group to achieve the material unwinding function. The motor unit includes a motor controller and a motor monitor. The motor controller controls the rotational speed of one or more motors in the motor unit. The motor monitor collects motor current data and motor temperature data. The tension roller group includes a tension sensor and an encoder. The tension sensor collects material tension data, and the encoder collects unwinding roller rotational speed data and / or material conveying speed. The braking assembly is used for emergency shutdown.

[0008] Furthermore, the emergency response system also includes a vision sensor, a forced cooling system, a backup power supply, and a waste recycling mechanism, wherein: the vision sensor is used to collect material edge position offset data and / or material surface defect data; the forced cooling system is used to provide forced heat dissipation for the motor group and / or the tension roller group; the motor group includes a backup motor; and the control system includes sensor channels and redundant sensor channels.

[0009] The second aspect of the present invention provides an emergency handling method for an unwinding system used in the production of nozzle materials, which is used in the above-mentioned emergency handling system and includes the following steps: Step A: Acquisition of key operating parameters of the unwinding system; Step B: Fault diagnosis and classification; Step C: Differentiated emergency handling; Step D: System recovery.

[0010] Furthermore, the key operating parameters of the unwinding system include one or more of the following data: motor current data, motor temperature data, material tension data, unwinding roller speed data, and material conveying speed.

[0011] Furthermore, the emergency handling system also includes a vision sensor, which is used to collect material edge position offset data and / or material surface defect data. The key operating parameters of the unwinding system also include the material edge position offset data and / or the material surface defect data.

[0012] Furthermore, the key operating parameters of the unwinding system are collected at a frequency of 5-10ms / time, 10-20ms / time, or 20-50ms / time.

[0013] Furthermore, the control system presets the normal threshold range of the key operating parameters of the unwinding system; the normal threshold range of the key operating parameters of the unwinding system can be adjusted through a human-machine interaction device or obtained through a network communication component.

[0014] Furthermore, the normal threshold range for the material tension data is set value ±15%; the normal threshold range for the unwinding roller speed is set value ±5%; and the normal threshold range for the material conveying speed is set value ±5%.

[0015] Furthermore, in step B, the criteria for fault judgment and classification are as follows: B1, abnormal tension fault: the tension data exceeds ±15% and the duration exceeds 200ms; B2, material breakage fault: the visual sensor detects an interruption in material continuity; or the tension data suddenly drops to near 0; B3, motor set fault: including the motor current exceeding the limit; B4, system signal fault: at least a portion of the key operating parameters of the unwinding system acquired by the control system is lost for more than 200ms; B5, high temperature fault: the bearing temperature of the motor set or the tension roller set is greater than 100℃.

[0016] Further, in step C, the differentiated emergency handling includes the following steps: Step C1 - Tension Abnormality Fault Emergency Handling: When a minor abnormality occurs, the speed of the motor group is adjusted to correct the tension in real time; when a severe abnormality occurs, the tension roller group decelerates, and stops when the speed of the tension roller group drops to 20% of the rated value, and the control system issues a first alarm; Step C2 - Material Fracture Fault Emergency Handling: The control system triggers an emergency stop and cuts off the material feed of subsequent processes; the emergency handling system also includes a waste recycling mechanism, which is activated; the control system issues a second alarm; Step C3 - Motor Group Fault Emergency Handling: The motor group includes a backup motor, the The control system instructs the motor controller to switch to the backup motor; or the control system starts a stop procedure and issues a third alarm; Step C4 - Emergency handling of system signal faults: The control system includes sensor channels and redundant sensor channels, and the control system automatically switches to the redundant sensor channel; or the control system enables temporary operation using preset empirical parameters; or the control system starts a stop procedure and issues a fourth alarm; Step C5 - Emergency handling of high temperature faults: The emergency handling system also includes a forced cooling system, and the control system starts the forced cooling system for forced heat dissipation; if the bearing remains above 90°C for more than 3 minutes, the control system starts a stop procedure and issues a fifth alarm.

[0017] Furthermore, system recovery includes: after the differentiated emergency handling is completed, the control system automatically performs a reset check; the reset check includes calibration of all or part of the key operating parameters of the unwinding system and no-load test run of the unwinding system; the human-machine interface prompts the operator to select manual recovery or automatic recovery; the control system saves the fault information to a local or network database.

[0018] This invention significantly improves fault response efficiency and reduces the escalation of losses. Traditional emergency response relies on manual intervention, resulting in a significant lag in fault detection and handling. This solution, however, uses sensors to collect parameters in real time, combined with automatic system analysis, to achieve rapid fault identification and classification, eliminating the time cost of manual troubleshooting. Whether it's immediate adjustment for abnormal tension or emergency shutdown due to material breakage, the corresponding handling process can be initiated instantly upon the occurrence of the fault, effectively shortening fault response time and minimizing cascading losses such as material waste and equipment damage caused by the continued failure.

[0019] This technical solution proposes a complete emergency handling method for various unexpected failures that may occur during the operation of the unwinding system. It aims to improve fault response speed, ensure production continuity, and reduce losses caused by failures through intelligent and differentiated handling methods. This solution breaks away from the traditional model that relies on manual intervention or simple shutdown protection. Through accurate fault diagnosis and classification, it takes targeted measures and achieves rapid system recovery.

[0020] The specific advantages are mainly reflected in the following aspects:

[0021] (I) Steps for collecting operating parameters

[0022] The system collects key parameters of the unwinding system in real time using sensors. These parameters include, but are not limited to, material tension, unwinding roll speed, material conveying speed, and material edge position offset, providing data support for subsequent fault diagnosis.

[0023] (II) Fault Diagnosis and Classification Steps

[0024] The system performs real-time analysis on the collected parameters and accurately classifies faults into major categories such as tension faults, material fracture faults, motor current over-limit faults, and sensor signal loss faults based on the changing characteristics of different parameters and preset fault judgment rules, laying the foundation for subsequent differentiated processing.

[0025] (III) Differentiated Emergency Response Procedures

[0026] Tension abnormality fault handling: When a minor abnormality is determined, the PID dynamic adjustment mechanism is activated to adjust the servo motor speed and correct the tension in real time to restore the tension to the normal range; when a serious abnormality occurs, a deceleration command is immediately issued and the tension roller group is adjusted to avoid the material from breaking due to excessive stretching.

[0027] Material fracture fault handling: Once a material fracture is detected, the system will immediately perform an emergency shutdown operation to prevent subsequent processes from being disrupted and equipment from being damaged due to the material fracture.

[0028] Motor equipment failure handling: If a backup motor is available, the system will automatically switch to the backup motor when a motor failure is detected to ensure continued system operation; if no backup motor is available, the system will be shut down to prevent the failure from escalating.

[0029] Sensor fault handling: When a sensor fails, the system automatically switches to the redundant sensor channel to ensure the continuity of parameter acquisition; if the redundant channel also fails or there is no backup, the preset empirical parameters are used to temporarily maintain the system operation, or the system stops working if the safety of operation cannot be guaranteed.

[0030] (iv) System recovery steps

[0031] After the fault is resolved, the system automatically performs a reset check, conducts a comprehensive test on all key components and parameters, and automatically restores normal operation after confirming that there are no abnormalities, ensuring smooth production.

[0032] This technical solution, through the coordinated operation of the above steps, achieves rapid response and precise handling of unwinding system faults, effectively improving system stability and production continuity, and providing strong support for the efficient operation of the unwinding system. Attached Figure Description

[0033] The above description of the present invention and the following detailed embodiments will be better understood when read in conjunction with the accompanying drawings. It should be noted that the drawings are merely examples of the claimed technical solutions.

[0034] Figure 1 This is a schematic diagram of the deployment of the emergency handling system of the unwinding system for the production of nozzle material according to the present invention;

[0035] Figure 2 This is a flowchart illustrating the emergency handling method of the unwinding system for the production of nozzle material according to the present invention.

[0036] The reference numerals in the attached figures are explained as follows:

[0037] 100: Motor set

[0038] 110: Motor controller

[0039] 200: Tension roller assembly

[0040] 210: Tension Sensor

[0041] 220: Encoder

[0042] 300: Visual Sensor

[0043] 800: Braking assembly

[0044] 900: Control System Detailed Implementation

[0045] The detailed features and advantages of this application are described below in the specific embodiments. The content of this description is sufficient to enable any person skilled in the art to understand the technical content of this application and implement it accordingly. Based on the specification, claims and drawings disclosed in this specification, a person skilled in the art can easily understand the related objectives and advantages of this application.

[0046] The invention will now be described with reference to the accompanying drawings, in which similar reference numerals denote similar elements. While specific structures and arrangements are discussed, it should be understood that this is done merely for illustrative purposes. Those skilled in the art will recognize that other structures and arrangements can be used without departing from the spirit and scope of the invention. It will be apparent to those skilled in the art that the invention can also be used in a variety of other applications.

[0047] In this specification and claims, several terms will be used, and unless otherwise indicated, these terms will be defined to have the following meanings:

[0048] The singular forms “a” and “the” include their corresponding plural forms. “At least one” means one or more, and “more” means two or more. “At least one of the following” or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one of a, b, or c can be expressed as: a, b, c, ab, ac, bc, or abc, where a, b, and c can be single or multiple.

[0049] All figures used to represent component amounts, properties (e.g., molecular weight), reaction conditions, etc., should be considered to be modified in all cases by the terms "within the unavoidable margin of error" or "about". Therefore, the numerical values ​​set forth herein are approximate and may vary depending on the desired properties sought to be obtained by the present invention. The principle of equivalents, which is applied to a minimum and not intended to limit the scope of the claims, should be applied, for example, each value should be interpreted at least according to the reported significant digits and by applying conventional rounding techniques.

[0050] It should be understood that the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. A and B can be singular or plural. Additionally, the character " / " in this article generally indicates an "or" relationship between the preceding and following related objects, but it can also represent an "and / or" relationship. Please refer to the context for a more accurate understanding.

[0051] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product is usually placed during use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0052] All other terms used herein for special definition are intended to have the general meaning understood by one of ordinary skill in the art, and in particular, meaning that one of ordinary skill in the art, upon reading the claims, specification and drawings of this patent, can directly and without doubt determine how the technical solution of this patent can be implemented.

[0053] Even if there are incomplete descriptions, omissions, or ambiguities in the grammar, words, punctuation, graphics, symbols, etc. of the claims, specification, and drawings of this patent, a person skilled in the art can still arrive at the only correct understanding by reading the claims, specification, and drawings as a whole without extensive reasoning or experimentation, and effectively exclude various incorrect interpretations that are not aimed at achieving the purpose of this patent.

[0054] Those skilled in the art would first choose to read the claims, specification, and drawings of this patent to reasonably interpret the terms; secondly, they would choose to refer to the relevant definitions in other documents published by the applicant before the filing date to reasonably interpret the terms; thirdly, they would choose the references cited in this patent to reasonably interpret the terms; and finally, they would choose to combine the technical dictionaries, technical manuals, reference books, textbooks, national or industry technical standards, etc., commonly used by those skilled in the art to reasonably interpret the terms.

[0055] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0056] The present invention aims to overcome the problems of slow emergency response and limited methods in the emergency handling of existing unwinding systems, and to provide an emergency handling method for unwinding systems.

[0057] refer to Figure 1 An emergency handling system for an unwinding system used in the production of nozzle materials according to the present invention includes a motor unit 100, a tension roller group 200, a vision sensor 300, a strong cooling system 500, a braking assembly 800, and a control system 900. Furthermore, the emergency handling system for an unwinding system used in the production of nozzle materials may also include a backup power supply (not shown in the figure).

[0058] The motor unit 100 drives the tension roller group 200 to achieve the unwinding function of the material. The motor unit 100 includes a motor controller 110, which receives control signals from the control system 900 to control the speed of one or more motors in the motor unit 100, thereby adjusting the tension applied to the material by the driving force of the motors via the tension roller group 200. The motor unit 100 also includes a motor monitor 120 for collecting status data such as motor current and temperature. Furthermore, the motor unit 100 may also include a backup motor (not shown in the figure).

[0059] The tension roller assembly 200 includes a tension sensor 210 and an encoder 220. The tension sensor 210 is used to collect material tension data, and the encoder is used to collect the unwinding roller speed and material conveying speed, etc. The control system 900 obtains the tension sensor data and encoder data to determine whether there is a tension abnormality.

[0060] The vision sensor 300 is used to collect data on the offset of the material edge position and surface defects (such as tears and holes). The control system 900 obtains the vision sensor data to determine whether there is material fracture.

[0061] When a high-temperature fault occurs, the control system 900 can activate the strong cooling system 500 to force heat dissipation for the motor group 100 or the tension roller group 200.

[0062] The braking assembly 800 is used for emergency stop. When a braking signal is received from the control system 900, the braking assembly 800 can completely stop the equipment, including the tension roller group 200, within 100ms.

[0063] The control system 900 includes a sensor channel connected to the aforementioned data acquisition device. In one specific embodiment, the control system 900 also includes a redundant sensor channel.

[0064] In addition, the emergency handling system for the unwinding system used in the production of nozzle material may also include a waste recycling mechanism (not shown in the figure).

[0065] refer to Figure 2 Based on the emergency handling system for an unwinding system used in the production of nozzle material of the present invention, an emergency handling method for the unwinding system can be implemented, which includes the following steps:

[0066] Step A: Steps for collecting key parameters of the unwinding system.

[0067] The control system 900 can collect motor status data such as motor current and temperature from the motor monitor 120, material tension data (accuracy ±1N) from the tension sensor 210, unwinding roller speed and material conveying speed (accuracy ±0.1m / min) from the encoder 220, and edge position offset (accuracy ±0.5mm) and surface defects (such as tears and holes) from the vision sensor 300. These data constitute the key parameters of the unwinding system.

[0068] In this step, the acquisition frequency of key parameters can be 5-10ms / time, 10-20ms / time, or 20-50ms / time to ensure rapid detection of sudden failures and reduce the risk of material loss and equipment damage.

[0069] Step B: Fault diagnosis and classification steps.

[0070] The normal threshold ranges of each key parameter are preset in the memory of the control system 900. The normal threshold ranges of each key parameter can be adjusted through the human-machine interaction device of the control system 900, or can be obtained through the network communication component of the control system 900.

[0071] In one specific implementation, the normal threshold range for tension data is set value ±15%, and the normal threshold range for unwinding roll speed and material conveying speed is set value ±5%.

[0072] In one specific implementation, when any critical parameter exceeds a threshold for a certain period of time, such as more than 100ms, 200ms, or 250ms, this can prevent momentary interference from causing false fault identification. In another specific implementation, the duration needs to be set according to different fault levels. For example, if the motor current is 120% of the rated value, it can be set to last for 1 minute for fault prediction; while if the motor current is 200% of the rated value, it can be set to last for 50ms for fault prediction, thereby enabling differentiated early warning responses for different levels of faults.

[0073] Fault classification is based on the abnormal characteristics of key parameters, for example:

[0074] B1. Tension abnormality fault:

[0075] The tension exceeds ±15% and the duration exceeds 200ms.

[0076] B2. Material fracture failure:

[0077] The visual sensor detects a break in the material's continuity; or the tension suddenly drops to near zero.

[0078] B3. Motor set failure:

[0079] When the motor current exceeds the limit, such as when the current is 150% of the rated value.

[0080] B4. System signal failure:

[0081] The sensor signal was lost for more than 200ms.

[0082] B5. High-temperature fault:

[0083] The bearing temperature of the motor unit or tension roller unit is greater than 100℃.

[0084] All of the above can be identified as equipment malfunctions.

[0085] Step C: Steps for differentiated emergency response.

[0086] Differentiated emergency response measures should be implemented based on fault classification, for example:

[0087] Step C1: Emergency handling of abnormal tension faults

[0088] For handling tension abnormality faults: When a minor abnormality is determined, such as a deviation of 15%-30% from the threshold, the control system 900 starts PID dynamic adjustment and instructs the motor controller 110 to adjust the speed of the motor group 100 to correct the tension in real time; when a serious abnormality occurs, such as a deviation of >30% from the threshold: the control system 900 immediately issues a deceleration command, instructing the braking component 800 to decelerate the tension roller group 200 to avoid material stretching and breakage. When the speed of the tension roller group drops to 20% of the rated value, the machine stops, and the control system 900 issues a first-level alarm through the human-machine interaction device.

[0089] Step C2: Emergency handling of material fracture failure

[0090] When a material breakage failure occurs, a rapid response is required. Within 10ms, the control system 900 instructs the braking component 800 to trigger an emergency stop, cutting off the material feed to subsequent processes. Simultaneously, the waste recycling mechanism can be activated to reel in the broken residual material onto the waste roller. The control system 900 issues a level-two alarm via the human-machine interface, prompting the operator to replace the roll.

[0091] Step C3: Emergency Handling of Motor Set Faults

[0092] When a motor equipment failure occurs, if a backup motor is available, the control system 900 instructs the motor controller 110 to switch to the backup motor, and the synchronization control module makes the speed of the backup motor consistent with that before the failure (speed deviation <2%); if there is no backup motor, the control system 900 starts the system shutdown procedure.

[0093] Step C4: Emergency Handling of System Signal Failures

[0094] When a system signal fails: the control system 900 automatically switches to the redundant sensor channel; if the redundant channel also fails or there is no backup, the preset experience parameters stored in the control system 900 are used for temporary operation or the control system 900 stops working, and at the same time the control system 900 issues a maintenance alarm through the human-machine interaction device.

[0095] Step C5: Emergency Handling of High Temperature Faults

[0096] When a high-temperature fault occurs: the control system 900 activates the strong cooling system 500 for forced heat dissipation. If the temperature remains high, such as when the bearing temperature exceeds 90°C for more than 3 minutes, the machine will shut down for protection.

[0097] Step D: System recovery steps.

[0098] After the fault is handled, the control system 900 automatically performs a reset check, including calibration of key parameters (such as zero-point tension correction) and no-load test run of the equipment (10 seconds). After confirming that there are no abnormalities, the human-machine interface prompts the operator to select "manual recovery" or "automatic recovery". During the recovery process, the tension and speed gradually increase to the set value. All fault information (time, type, handling process, parameter curve) is stored in the local or network database.

[0099] In one specific implementation, the equipment handles tension abnormality faults. For example, if the tension in the unwinding system is set to 50N, and during operation, the tension suddenly rises to 65N (exceeding the 15% threshold) due to a material joint: the tension sensor detects the abnormality within 10ms and transmits the data to the controller; the controller determines that it is a slight tension abnormality, starts PID regulation, adjusts the servo motor speed, completes the motor speed adaptation within 200ms, the tension recovers to 52N, and the system continues to run without shutdown.

[0100] In one specific implementation, when a material breakage fault is handled, the vision sensor detects an interruption in material continuity, and at the same time, the tension sensor value drops sharply to 0. The controller immediately issues an emergency stop command, and the machine stops completely within 100ms. The cutting device cuts off the material being transported subsequently, the waste recycling mechanism starts, and the broken paper is wound up to the waste roller. The system is restarted after being manually confirmed to be normal.

[0101] In one specific implementation, regarding motor fault handling, if the unwinding main motor on the nozzle production line experiences a sudden overcurrent, the motor controller detects the abnormal current and sends a fault signal to the system controller. The controller determines that it is a motor fault, starts the backup motor, or issues a shutdown command, and the system completely shuts down within 200ms. The system is restarted after manual confirmation that it is back to normal.

[0102] Based on the same inventive concept, this application also provides a computer system including a memory, a processor, and computer-readable instructions stored in the memory and executable on the processor. When the processor executes the program, it implements the above-mentioned emergency handling method for the unwinding system of the nozzle material production.

[0103] The computer system can be a server. The computer system includes a processor, non-volatile storage medium, internal memory, input devices, output devices (display screen, sound player, printer), and a network interface connected via a system bus. The non-volatile storage medium of the computer system can store the operating system and computer-readable instructions. When these computer-readable instructions are executed, the processor can perform the emergency handling method for the unwinding system of the nozzle material production according to the embodiments of this application. The specific implementation process of this method can be found in [reference needed]. Figure 1 The specific details will not be elaborated here.

[0104] The processor of this computer system provides computing and control capabilities, supporting the operation of the entire system. The internal memory can store computer-readable instructions, which, when executed by the processor, enable the processor to perform emergency handling methods for the unwinding system used in the production of the nozzle material. The computer system's input devices are used for inputting various parameters, the display screen is used for display, and the network interface is used for network communication.

[0105] Based on the same inventive concept, this application provides a computer-readable storage medium storing computer-readable instructions, which, when executed by a processor, implement the steps in the above-described emergency handling method for the unwinding system of the nozzle material production.

[0106] The memory in this application embodiment can be volatile memory or non-volatile memory, or it can include both volatile and non-volatile memory. The non-volatile memory can be read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), or flash memory. The volatile memory can be random access memory (RAM), which is used as an external cache. By way of example, but not limitation, many forms of random access memory (RAM) are available, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate synchronous DRAM (DDR SDRAM), enhanced synchronous DRAM (ESDRAM), synchronous linked DRAM (SLDRAM), and direct rambus RAM (DR RAM).

[0107] The above embodiments can be implemented, in whole or in part, by software, hardware (such as circuits), firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, as a computer program product. A computer program product includes one or more computer instructions or computer programs.

[0108] When computer instructions or computer programs are loaded or executed on a computer, all or part of the processes or functions according to the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., infrared, wireless, microwave, etc.) means.

[0109] Computer-readable storage media can be any available medium that a computer can access, or a data storage device such as a server or data center that includes one or more sets of available media. Available media can be magnetic media (e.g., floppy disks, hard disks, magnetic tapes), optical media (e.g., DVDs), or semiconductor media. Semiconductor media can be solid-state drives (SSDs).

[0110] It should be understood that in the various embodiments of this application, the order of the above-mentioned processes does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0111] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0112] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the devices, apparatuses, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0113] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0114] In this specification, references to "an embodiment" or "a specific implementation" mean that a particular feature, structure, or characteristic described in connection with that embodiment / specific implementation is included in at least one embodiment / specific implementation of the invention. Therefore, the phrase "in one embodiment / specific implementation" appearing in various places in this specification does not necessarily refer to the same embodiment / setting, but rather to potentially different embodiments. Furthermore, specific features, structures, or characteristics may be combined in one or more embodiments / settings in any suitable manner, as will be apparent to those skilled in the art from this disclosure.

[0115] Similarly, it should be understood that in the above description of exemplary embodiments / specific implementations of the invention, various features of the invention are sometimes combined in a single embodiment / specific implementation or its figures and description, with the aim of simplifying the disclosure and aiding in the understanding of one or more of the various aspects of the invention. However, the method of description in this patent should not be construed as reflecting an intention that the claimed features of the invention are more than those expressly stated in each claim, except where explicitly stated otherwise or in obvious technical contradiction or exclusion. Rather, the inventive aspect reflected in the claims lies in not all the features of a single foregoing disclosed embodiment / specific implementation. Therefore, the claims following the detailed description are expressly incorporated herein by reference, each claim existing independently as a separate embodiment / specific implementation of the invention.

[0116] Furthermore, while some embodiments / specific implementations described herein include, but are not limited to, other features included in other embodiments / specific implementations, combinations of features from different embodiments / specific implementations are intended to be within the scope of the invention and form different embodiments / specific implementations, as will be understood by those skilled in the art. For example, in the following claims, embodiments / specific implementations of any claim can be used in any combination.

[0117] The terms and expressions used in this specification are for illustrative purposes and not for limitation. In using these terms and expressions, it is not intended to exclude any equivalents of the features or portions thereof shown and described, but rather to recognize that various modifications may be possible within the scope of the invention.

[0118] Therefore, it should be understood that although the invention has been specifically disclosed through preferred embodiments, exemplary embodiments and optional features, those skilled in the art may take variations or modifications of the concepts disclosed herein, and such variations and modifications are therefore considered to be within the scope of the invention as defined by the appended claims.

[0119] The specific embodiments given in this specification are examples of useful implementations of the present invention. It will be apparent to those skilled in the art that the present invention can be implemented using many variations of the devices, device components, and method steps disclosed in this specification.

[0120] The foregoing description of specific embodiments fully discloses the general features of the present invention, enabling others to easily modify and / or adapt such specific embodiments for various applications by applying knowledge within the scope of the art, without conducting excessive experimentation and without departing from the general concept of the present invention.

[0121] Therefore, based on the teachings and guidance provided herein, it is intended that such modifications and alterations be included within the meaning and scope of equivalents of the disclosed embodiments. It should be understood that the wording or terminology used herein is for descriptive purposes and is not intended to be limiting; thus, the wording or terminology in this specification will be interpreted by those skilled in the art based on the foregoing teachings and guidance.

[0122] Furthermore, the scope of the invention should not be limited to any of the exemplary embodiments described above, but only to the appended claims and their equivalents.

Claims

1. An emergency handling system for an unwinding system used in the production of nozzle rod materials, characterized in that, The emergency response system includes: a motor unit, a tension roller unit, a braking assembly, and a control system, wherein: The motor unit is used to drive the tension roller group to achieve the unwinding function of the material. The motor unit includes a motor controller and a motor monitor. The motor controller controls the speed of one or more motors in the motor unit, and the motor monitor is used to collect motor current data and motor temperature data. The tension roller assembly includes a tension sensor and an encoder. The tension sensor is used to collect material tension data, and the encoder is used to collect unwinding roller speed data and / or material conveying speed. The braking assembly is used for emergency stopping.

2. The emergency response system according to claim 1, characterized in that, The emergency response system also includes a visual sensor, a powerful cooling system, a backup power supply, and a waste recycling mechanism, wherein: The vision sensor is used to collect data on the offset of material edge position and / or data on material surface defects; The powerful cooling system is used to force heat dissipation from the motor assembly and / or the tension roller assembly; The motor set includes a spare motor; The control system includes sensor channels and redundant sensor channels.

3. An emergency handling method for an unwinding system used in the production of nozzle materials, used in the emergency handling system as described in claim 1, characterized in that, Includes the following steps: Step A: Acquisition of key operating parameters for the unwinding system; Step B: Fault diagnosis and classification; Step C: Differentiated emergency response; Step D: System recovery.

4. The emergency response method according to claim 3, characterized in that, The key operating parameters of the unwinding system include one or more of the following data: motor current data, motor temperature data, material tension data, unwinding roller speed data, and material conveying speed; The emergency handling system also includes a vision sensor, which is used to collect material edge position offset data and / or material surface defect data. The key operating parameters of the unwinding system also include the material edge position offset data and / or the material surface defect data.

5. The emergency response method according to claim 4, characterized in that, The key operating parameters of the unwinding system are collected at a frequency of 5-10ms / time, 10-20ms / time, or 20-50ms / time.

6. The emergency response method according to claim 4, characterized in that, The control system presets the normal threshold range of the key operating parameters of the unwinding system; the normal threshold range of the key operating parameters of the unwinding system can be adjusted through a human-machine interaction device or obtained through a network communication component.

7. The emergency response method according to claim 6, characterized in that, The normal threshold range for the material tension data is ±15% of the set value; the normal threshold range for the unwinding roller speed is ±5% of the set value; and the normal threshold range for the material conveying speed is ±5% of the set value.

8. The emergency response method according to claim 4, characterized in that, In step B, the basis for fault judgment and classification is as follows: B1. Tension Abnormality Fault: The tension data exceeds ±15% and the duration exceeds 200ms; B2. Material fracture failure: The vision sensor detects an interruption in material continuity; Or the tension data suddenly drops to near 0; B3. Motor set failure: When the motor current exceeds the limit; B4. System signal failure: At least some of the key operating parameters of the unwinding system acquired by the control system are lost for more than 200ms. B5. High temperature fault: The bearing temperature of the motor unit or the tension roller unit is greater than 100℃.

9. The emergency response method according to claim 8, characterized in that, In step C, the differentiated emergency response includes the following steps: Step C1 - Emergency Handling of Tension Abnormality: In case of minor abnormality, adjust the speed of the motor group to correct the tension in real time; in case of severe abnormality, the tension roller group decelerates and stops when the speed of the tension roller group drops to 20% of the rated value, and the control system issues the first alarm. Step C2 - Emergency Handling of Material Fracture Failure: The control system triggers an emergency shutdown and cuts off the material feed to subsequent processes; the emergency handling system also includes a waste recycling mechanism, which is activated; the control system issues a second alarm. Step C3 - Emergency Handling of Motor Set Failure: The motor set includes a backup motor, and the control system instructs the motor controller to switch to the backup motor; or the control system initiates a stop procedure and issues a third alarm. Step C4 - Emergency Handling of System Signal Failure: The control system includes a sensor channel and a redundant sensor channel. The control system automatically switches to the redundant sensor channel; or the control system enables temporary operation with preset empirical parameters; or the control system starts a stop procedure and issues a fourth alarm. Step C5 - High Temperature Fault Emergency Handling: The emergency handling system also includes a forced cooling system. The control system activates the forced cooling system to dissipate heat. If the bearing remains above 90°C for more than 3 minutes, the control system initiates a stop procedure and issues a fifth alarm.

10. The emergency response method according to claim 4, characterized in that, The system recovery includes: After the differentiated emergency handling is completed, the control system automatically performs a reset check; the reset check includes calibration of all or part of the key operating parameters of the unwinding system, and no-load test run of the unwinding system; the human-machine interface prompts the operator to choose manual recovery or automatic recovery; the control system saves the fault information to a local or network database.

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