Device and method for detecting ingredient supply state of mixer

Abstract

The invention relates to a device and a method for detecting the ingredient supply state of a mixer. The device for detecting the ingredient supply state of the mixer mainly comprises a transition charging barrel used for connecting an ingredient charging barrel and a cache charging barrel, and an optical fiber sensor arranged at the transition charging barrel, wherein the optical fiber sensor comprises a processing module, and an optical fiber sensor sending end and an optical fiber sensor receiving end which are connected with the processing module; wherein the optical fiber sensor sending end and the optical fiber sensor receiving end are located on the two sides of the transition charging barrel respectively and are oppositely arranged, and the part, used for sending optical signals, of the optical fiber sensor sending end and the part, used for receiving the optical signals, of the optical fiber sensor receiving end are both located in the transition charging barrel. According to the invention, the supply abnormity of the ingredients can be found in time in the production process, and batch quality accidents are avoided.

Description

Technical Field

[0001] This application relates to the field of mixing machine technology, and in particular to a mixing machine batching supply status detection device and method. Background Technology

[0002] A mixing machine is a plastic particle mixing and feeding device, typically installed on an extruder where the raw materials need to be mixed from multiple ingredients in a specific ratio. The mixing machine's feeding unit generally consists of a hopper, motor, coupling, screw, and barrel. The main feeding motor's speed serves as the base speed, while the speeds of the other feeding motors are set according to the ratio of the main and feed ingredients. Thus, when the extruder's buffer hopper is low on material, several feeding units simultaneously supply material for mixing, achieving the mixing and feeding of the materials into the buffer hopper.

[0003] The aforementioned ingredient supply device has the following problems: some ingredients are prone to clumping, which can lead to screw blockage. Due to these factors, one or more ingredients may fail to be supplied normally. When this happens, the controller cannot effectively detect it, easily leading to incorrect ingredient ratios and affecting product quality. Furthermore, the absence of a certain ingredient is not easily noticeable in the product's appearance; the problem can only be discovered during subsequent testing. By then, a batch of product quality issues has already occurred, causing significant losses.

[0004] Therefore, how to overcome the shortcomings of existing technologies and solve the problem of batch quality accidents caused by abnormal material supply in the material supply device of existing mixers is a problem to be solved in this technical field. Summary of the Invention

[0005] In view of the above-mentioned defects or improvement needs of the prior art, and in order to solve the problem of batch quality accidents caused by abnormal material supply in the material supply device of the existing mixer, this application provides a material supply status detection device and method for a mixer, which can detect abnormal material supply in a timely manner during the production process and avoid batch quality accidents.

[0006] The embodiments of this application adopt the following technical solutions: In a first aspect, this application provides a mixing machine batching supply status detection device, including a transition cylinder 1 for connecting a batching cylinder 100 and a buffer cylinder 200, and an optical fiber sensor disposed at the transition cylinder 1. The optical fiber sensor includes a processing module and an optical fiber sensor transmitter 2 and an optical fiber sensor receiver 3 connected to the processing module; wherein: The fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 are located on opposite sides of the transition cylinder 1. The portion of the fiber optic sensor transmitter 2 used to transmit optical signals and the portion of the fiber optic sensor receiver 3 used to receive optical signals are both located inside the transition cylinder 1.

[0007] By adopting the above technical solution, during the batching process, when material passes through the transition cylinder 1, the fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 work together to detect material obstruction, indicating that the batching process is normal. Conversely, if the fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 detect no material obstruction, it means that no material has passed through, indicating that the batching process is abnormal, possibly due to material agglomeration or blockage. This triggers a warning, allowing operators to understand and resolve the problem promptly. This solution can detect abnormal material supply during production in a timely manner, preventing batch quality accidents.

[0008] In some embodiments, a base 4 is provided on one side of the transition cylinder 1, and mounting plates 5 are provided on both sides of the base 4. The fiber optic sensor transmitting end 2 is mounted on the mounting plate 5 on one side, and the fiber optic sensor receiving end 3 is mounted on the mounting plate 5 on the other side.

[0009] By adopting the above technical solution, the fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 are mounted on the mounting plate 5 and then cooperated with the transition cylinder 1, which makes it convenient to remove the fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 for cleaning or replacement.

[0010] In some embodiments, the transition cylinder 1 has a cutout 101 at a position corresponding to the mounting plate 5, and the shape of the cutout 101 matches the shape of the mounting plate 5 facing the transition cylinder 1; the mounting plate 5 has a through groove 501, and the part of the fiber optic sensor transmitting end 2 used to transmit optical signals and the part of the fiber optic sensor receiving end 3 used to receive optical signals enter the interior of the transition cylinder 1 through the through groove 501.

[0011] By adopting the above technical solution, the part of the fiber optic sensor transmitter 2 used to transmit optical signals and the part of the fiber optic sensor receiver 3 used to receive optical signals are located inside the transition cylinder 1, thereby enabling the detection function of the material inside the transition cylinder 1.

[0012] In some embodiments, slide rails 6 are provided on both sides of the base 4, and sliders 7 are provided on the slide rails 6, with the mounting plate 5 fixed on the sliders 7.

[0013] By adopting the above technical solution, the slider 7 drives the mounting plate 5 to move on the slide rail 6, which can be easily connected with the transition cylinder 1. The mounting plate 5 can also be easily removed to clean or replace the fiber optic sensor transmitter 2 and fiber optic sensor receiver 3 on the mounting plate 5.

[0014] In some embodiments, the transition cylinder 1 is provided with at least two compressed air nozzles 8, one of which is aligned with the part of the fiber optic sensor transmitting end 2 used to transmit optical signals, and the other is aligned with the part of the fiber optic sensor receiving end 3 used to receive optical signals.

[0015] By adopting the above technical solution, compressed air nozzle 8 can be used to clean the surface dust of the fiber optic sensor transmitter 2 and fiber optic sensor receiver 3, reducing the frequency of manual cleaning.

[0016] In some embodiments, the transition cylinder 1 is installed at an angle between the dispensing cylinder 100 and the buffer cylinder 200, and the end of the transition cylinder 1 connected to the dispensing cylinder 100 is higher than the end connected to the buffer cylinder 200.

[0017] By adopting the above technical solution, after the material enters the transition cylinder 1 from the batching cylinder 100, it can smoothly roll along the inclined slope into the buffer cylinder 200 without the need for additional transmission power.

[0018] Secondly, this application provides a method for detecting the feeding status of a mixer, applied to the mixer feeding status detection device described in the first aspect, comprising: The light reception threshold of the fiber optic sensor receiver 3 is set. When the light reception of the fiber optic sensor receiver 3 is greater than the light reception threshold, the processing module generates a first-level output signal to determine that there is no material obstruction. When the light reception of the fiber optic sensor receiver 3 is less than the light reception threshold, the processing module generates a second-level output signal to determine that there is material obstruction. The output signal of the processing module is connected to the controller. After the batching process starts, the controller's scan cycle t is obtained. The state of the output signal is checked once in each scan cycle. If the output signal is at the second level, then t... n =t n-1 +t; where t n t represents the total time during the batching process when materials obstruct the flow. n-1 is the total time that the material obscures the material during the previous scan cycle, and n is the total number of scan cycles that the material obscures the material during the batching process; Set the comparison time T1, if t during the batching process n If the value is >T1, the material supply status is determined to be normal; otherwise, the material supply status is determined to be abnormal, and an alarm is issued.

[0019] By adopting the above technical solution, it is possible to determine whether the material supply status is normal, thereby enabling timely detection of abnormal material supply during the production process and avoiding batch quality accidents.

[0020] In some embodiments, the method includes: after the feeding stops, determining the state of the output signal once per scan cycle; if the output signal is at the second level, then t m =t m-1 +t; where t m t represents the total time during which materials obstruct the feed during the feeding stop process. m-1 is the total time during the previous scan cycle when there was material obstruction, and m is the total number of scan cycles during the feeding stop process when there was material obstruction; Set the comparison time T2. If the batching process stops, t m If T2 is detected, the fiber optic sensor is deemed to be malfunctioning, and an alarm is issued.

[0021] By adopting the above technical solution, it is possible to determine whether the fiber optic sensor is malfunctioning. If it is malfunctioning, an alarm will be automatically triggered to remind the operator to replace or clean the fiber optic sensor.

[0022] In some embodiments, the following is included: during initial operation, the light intensity of the fiber optic sensor transmitter 2 is set to a low value lux_s_1, and the light reception threshold lux_thr of the fiber optic sensor receiver 3 is adjusted based on this. At this time, the light reception of the fiber optic sensor receiver 3 when there is no material obstruction is lux_p, and a preset light reception warning value lux_p_lim is set. When the light received by the fiber optic sensor receiver 3 drops below the preset light received warning value lux_p_lim when there is no material obstruction, the light intensity of the fiber optic sensor transmitter 2 is adjusted upward so that the light received by the fiber optic sensor receiver 3 is restored to lux_p. After multiple adjustments, the light intensity at the transmitting end 2 of the fiber optic sensor reaches its upper limit. Then, when the amount of light received at the receiving end 3 of the fiber optic sensor drops to the light reception threshold lux_thr, an automatic alarm is triggered.

[0023] By adopting the above technical solution, the relevant parameters of the fiber optic sensor regarding light intensity can be automatically adjusted, thereby making full use of the performance of the fiber optic sensor and reducing the number of times the fiber optic sensor needs to be manually cleaned.

[0024] In some embodiments, the following is included: during initial operation, the light intensity of the fiber optic sensor transmitter 2 is set to the maximum value lux_s_max, and the light reception threshold lux_thr_1 of the fiber optic sensor receiver 3 is adjusted based on this. At this time, the light reception of the fiber optic sensor receiver 3 when there is no material obstruction is lux_p, and the preset light reception warning value lux_p_lim_1 is used. When the light received by the fiber optic sensor receiver 3 drops below the preset light received warning value lux_p_lim_1 when there is no material obstruction, the light received threshold of the fiber optic sensor receiver 3 is adjusted to lux_thr_2 and the light received warning value is adjusted to lux_p_lim_2 according to a certain ratio. After multiple adjustments, the light reception threshold of the fiber optic sensor receiver 3 reaches the lower limit and an alarm is automatically triggered.

[0025] By adopting the above technical solution, the relevant parameters of the fiber optic sensor regarding the light reception threshold can be automatically adjusted, thereby making full use of the performance of the fiber optic sensor and reducing the number of times the fiber optic sensor needs to be manually cleaned.

[0026] Compared with the prior art, the beneficial effects of this application include, but are not limited to, the following: 1. During the batching process, when material passes through the transition cylinder 1, the fiber optic sensor transmitter 2 and receiver 3 work together to detect material obstruction, indicating normal batching. Conversely, if the fiber optic sensor transmitter 2 and receiver 3 detect no material obstruction, it means no material is passing through, indicating abnormal batching, possibly due to material clumping or blockage. This triggers a warning, allowing operators to promptly understand and resolve the problem. This solution enables timely detection of abnormal material supply during production, preventing batch quality incidents.

[0027] 2. Using slider 7 to drive mounting plate 5 to move on slide rail 6, it can be easily connected with transition cylinder 1, and can also be easily removed to clean or replace fiber optic sensor transmitter 2 and fiber optic sensor receiver 3 on mounting plate 5.

[0028] 3. It can automatically adjust the relevant parameters of the fiber optic sensor regarding light intensity and light reception threshold, thereby making full use of the performance of the fiber optic sensor and reducing the number of times the fiber optic sensor needs to be cleaned manually. Attached Figure Description

[0029] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments of this application will be briefly described below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the structure of a mixing machine batching supply status detection device provided in an embodiment of this application; Figure 2 This is a schematic diagram illustrating the actual application of the mixing machine batching supply status detection device provided in the embodiments of this application; Figure 3 A schematic diagram of the buffer cylinder provided in an embodiment of this application; Figure 4 This is a schematic diagram of the structure of the transition cylinder provided in an embodiment of this application; Figure 5 This is a schematic diagram of the structure of the mounting plate provided in the embodiments of this application; Figure 6 This is a schematic diagram of the slide rail slider arrangement position provided in the embodiments of this application; Figure 7 This is a schematic diagram showing the arrangement of compressed air nozzles in an embodiment of this application. Figure 8 A flowchart of a method for detecting the material supply status of a mixer provided in this application embodiment; Figure 9 This is a flowchart of a fiber optic sensor malfunction detection method provided in an embodiment of this application. Figure 10 A flowchart illustrating a method for adaptively adjusting light intensity based on a decrease in the amount of light received, as provided in an embodiment of this application. Figure 11 A line graph showing the adaptive adjustment of light intensity based on a decrease in the amount of light received, provided in an embodiment of this application; Figure 12 A flowchart illustrating a method for adaptively adjusting the light reception threshold and light reception warning value based on a decrease in light reception, as provided in an embodiment of this application. Figure 13 A line graph showing the adaptive adjustment of the light reception threshold and light reception warning value based on the decrease in light reception provided in this application embodiment. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0032] Furthermore, the technical features involved in the various embodiments of this application described below can be combined with each other as long as they do not conflict with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0033] Example 1 like Figure 1As shown in the figure, this application provides a material supply status detection device for a mixing machine, including a transition cylinder 1 and an optical fiber sensor disposed at the transition cylinder 1. The optical fiber sensor includes a processing module and an optical fiber sensor transmitter 2 and an optical fiber sensor receiver 3 connected to the processing module. The optical fiber sensor transmitter 2 and the optical fiber sensor receiver 3 are respectively located on both sides of the transition cylinder 1 and are arranged opposite to each other. The portion of the optical fiber sensor transmitter 2 used to transmit optical signals and the portion of the optical fiber sensor receiver 3 used to receive optical signals are both located inside the transition cylinder 1. Through the above technical solution, during the material supply process, when material passes through the transition cylinder 1, the optical fiber sensor transmitter 2 and the optical fiber sensor receiver 3 can detect material obstruction by working together, indicating that the material supply process is normal. Conversely, if the optical fiber sensor transmitter 2 and the optical fiber sensor receiver 3 detect no material obstruction, it indicates that no material has passed through, suggesting that the material supply process is abnormal, possibly due to material agglomeration or blockage, thus issuing a warning to allow operators to understand and resolve the problem promptly. This solution can promptly detect abnormalities in the material supply during production, preventing batch quality incidents. By detecting the state of plastic particles during the descent and rolling phase, the solution achieves accurate monitoring of the material supply status in the mixer, resulting in higher reliability.

[0034] refer to Figure 2 As shown, in practical use, the transition cylinder 1 connects the batching cylinder 100 and the buffer cylinder 200. One buffer cylinder 200 corresponds to multiple transition cylinders 1 and multiple batching cylinders 100. Each batching cylinder 100 is equipped with a storage hopper, motor, coupling, screw, and other components at its rear end to transport the batching material into the batching cylinder 100. This conveying method and structure are existing technology and will not be described in detail. In the above structure, one transition cylinder 1 and one batching cylinder 100 are used to transport one type of batching material. The combination of multiple sets of transition cylinders 1 and batching cylinders 100 can also transport multiple sets of batching materials, thereby forming the required mixed batching material within the buffer cylinder 200. Preferably, the transition cylinder 1 is installed at an incline between the feeding cylinder 100 and the buffer cylinder 200, and the end of the transition cylinder 1 connected to the feeding cylinder 100 is higher than the end connected to the buffer cylinder 200; in this way, after the material enters the transition cylinder 1 from the feeding cylinder 100, it can smoothly roll along the inclined surface into the buffer cylinder 200 without the need for additional transmission power.

[0035] refer to Figure 3 As shown, in some embodiments, the cross-section of the buffer cylinder 200 is polygonal, wherein each side of the buffer cylinder 200 has an inlet 210 connected to the transition cylinder 1. For example Figure 2 , Figure 3The buffer cylinder 200 shown has a quadrilateral cross-section, with feed inlets 210 on each of its four sides, allowing it to connect to up to four sets of transition cylinders 1. Figure 2 Taking only three sets of transition cylinders 1 as an example, the fourth feed port 210 can be covered by a sealing plate.

[0036] refer to Figure 4 As shown, in some embodiments, both ends of the transition cylinder 1 are provided with connecting blocks 102 to be fixedly connected to the dispensing cylinder 100 and the buffer cylinder 200 through the connecting blocks 102. The diameter of the connecting blocks 102 is larger than the diameter of the transition cylinder 1, so that the connecting blocks 102 can be fixedly connected to the dispensing cylinder 100 and the buffer cylinder 200 by bolts at the part of the connecting blocks 102 that extends beyond the outer periphery of the transition cylinder 1; of course, the connecting blocks 102 can also be fixedly connected to the dispensing cylinder 100 and the buffer cylinder 200 by welding.

[0037] refer to Figure 1 As shown, in some embodiments, a base 4 is provided on one side of the transition cylinder 1. The base 4 can be bolted or welded to the transition cylinder 1, or bolted or welded to the buffer cylinder 200; no limitation is made here. Mounting plates 5 are provided on both sides of the base 4 of the transition cylinder 1. The fiber optic sensor transmitter 2 is mounted on one mounting plate 5, and the fiber optic sensor receiver 3 is mounted on the other mounting plate 5. Corresponding screw holes are provided on the fiber optic sensor transmitter 2, the fiber optic sensor receiver 3, and the mounting plate 5 for connection by screws. By setting the fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 on the mounting plate 5 and then cooperating with the transition cylinder 1, it is convenient to remove the mounting plate 5 later, and then remove the fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 for cleaning or replacement.

[0038] refer to Figure 4 and Figure 5As shown, in some embodiments, the transition cylinder 1 has cutouts 101 on both sides corresponding to the mounting plate 5. The shape of the cutouts 101 matches the shape of the mounting plate 5 facing the transition cylinder 1. Specifically, the mounting plate 5 can be T-shaped overall, and the shape of the mounting plate 5 facing the transition cylinder 1 can be L-shaped. Correspondingly, the cutouts 101 of the transition cylinder 1 are also L-shaped notches, so that the L-shaped side of the mounting plate 5 can abut against the L-shaped cutout 101 of the transition cylinder 1, and precisely cover the notch. Furthermore, the mounting plate 5 has a through groove 501, through which the part of the fiber optic sensor transmitting end 2 for transmitting optical signals and the part of the fiber optic sensor receiving end 3 for receiving optical signals enter the interior of the transition cylinder 1. Through the above technical solution, the part of the fiber optic sensor transmitting end 2 for transmitting optical signals and the part of the fiber optic sensor receiving end 3 for receiving optical signals are located inside the transition cylinder 1, thereby realizing the detection function of the material inside the transition cylinder 1. Furthermore, the shape and size of the through groove 501 can be set to be consistent with the shape and size of the part of the fiber optic sensor transmitter 2 used to transmit optical signals and the part of the fiber optic sensor receiver 3 used to receive optical signals. In this way, no gaps are left, and materials are prevented from leaking out from the gaps.

[0039] refer to Figure 6 and Figure 7 As shown, in some embodiments, slide rails 6 are provided on both sides of the base 4, and sliders 7 are provided on the slide rails 6. The mounting plate 5 is fixed on the sliders 7, and the mounting plate 5 and the sliders 7 are provided with corresponding screw holes for fixing with screws. Specifically, the slide rail 6 is configured as two sections, located on both sides of the transition cylinder 1 respectively. The direction of the slide rail 6 is aligned with the cut 101 of the transition cylinder 1, so that the mounting plate 5 can be driven into or out of the cut 101 by the sliders 7. Furthermore, the sliders 7 and the slide rails 6 are also provided with screw holes at corresponding positions. After the mounting plate 5 is slid into place by the sliders 7, the sliders 7 and the slide rails 6 can be fixed with screws. When it is necessary to remove the mounting plate 5 from the cut 101, the screws are loosened, and the sliders 7 can remove the mounting plate 5 from the cut 101. Through the above technical solution, the mounting plate 5 is moved on the slide rails 6 by the sliders 7, which can be conveniently connected with the transition cylinder 1, and the mounting plate 5 can be easily removed for cleaning or replacement of the fiber optic sensor transmitter 2 and fiber optic sensor receiver 3 on the mounting plate 5.

[0040] refer to Figure 7As shown, in some embodiments, at least two compressed air nozzles 8 are provided inside the transition cylinder 1. One compressed air nozzle 8 is aligned with the portion of the fiber optic sensor transmitting end 2 used for transmitting optical signals, and the other compressed air nozzle 8 is aligned with the portion of the fiber optic sensor receiving end 3 used for receiving optical signals. The compressed air nozzles 8 are fixed to the inner wall of the transition cylinder 1 by welding or bolting with connecting pieces. (Refer to...) Figure 4 As shown, the transition cylinder 1 is also provided with a nozzle air pipe through hole 103 at a position corresponding to the compressed air nozzle 8, so that the air pipe of the compressed air nozzle 8 can be connected to the outside, thereby realizing the blowing of external compressed air into the transition cylinder 1. Through the above technical solution, the compressed air nozzle 8 can be used to clean the surface dust of the fiber optic sensor transmitter end 2 and the fiber optic sensor receiver end 3, reducing the frequency of manual cleaning.

[0041] It should be noted that the compressed air nozzle 8 has an automatic cleaning function, which can reduce the number of times the sensor needs to be cleaned manually. When the automatic cleaning is no longer sufficient, the mounting plate 5 can be easily moved out of the sensor's transmitting and receiving ends by the slider 7, so that manual cleaning can be performed.

[0042] The above is a detailed description of the structure of the embodiments of this application. The embodiments of this application will be further described below through the overall working principle.

[0043] The mixing machine feeding status detection device provided in this embodiment mainly includes a transition cylinder 1, a fiber optic sensor, a compressed air nozzle 8, a T-shaped mounting plate 5, a slider 7, a slide rail 6, and a base 4. The transition cylinder 1 connects the feeding cylinder 100 and the extruder's buffer hopper (or buffer cylinder 200). The transition cylinder 1 is installed at an angle, creating a height difference between the outlet of the feeding cylinder 100 and the inlet of the extruder's buffer cylinder 200. This ensures that the feed can smoothly roll along the bottom slope of the transition cylinder 1 into the extruder's buffer cylinder 200. The L-shaped bottom and sides of the tail end of the transition cylinder 1 are symmetrically cut off to facilitate the sliding of the T-shaped mounting plates 5 on both sides. The fiber optic sensor consists of a transmitter, a receiver, and a processing module. The transmitter and receiver are mounted opposite each other on the bottom of the T-shaped mounting plates 5. The processing module needs to set an appropriate light reception threshold based on the characteristics of the material being detected. If particles roll off during feeding and block the light between the transmitter and receiver, causing the light reception to fall below the set threshold, the processing module will invert the output signal level. The bottom of the T-shaped mounting plates 5 has rectangular slots. The receiver of the fiber optic sensor receives the light emitted from the transmitter through these slots. The T-shaped mounting plates 5 are fixed to the slider 7, and the slider 7 and slide rail 6 are mounted on the base 4. When the fiber optic sensor needs to operate, sliding the slider 7 closes one side of the T-shaped mounting plate 5 with the L-shaped cut of the transition cylinder 1, and then locking the slider 7. When dust accumulates after prolonged use and affects the normal operation of the sensor, the slider 7 can be slid out to facilitate cleaning of the transmitter and receiver surfaces. Because dust from plastic particles can easily accumulate on the surfaces of the optical fiber transmitter and receiver, causing false detections by the sensors, compressed air nozzles are designed at the transmitter and receiver of the optical fiber to automatically clean the dust on the surface at regular intervals in order to reduce the frequency of manual cleaning.

[0044] In summary, in the material preparation process of this embodiment, when material passes through the transition cylinder 1, the fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 work together to detect material obstruction, indicating that the material preparation process is normal. Conversely, if the fiber optic sensor transmitter 2 and the fiber optic sensor receiver 3 detect no material obstruction, it means that no material has passed through, indicating that the material preparation process is abnormal, possibly due to material agglomeration or blockage. This triggers a warning, allowing operators to promptly understand and resolve the problem. This solution can detect abnormal material supply during production in a timely manner, preventing batch quality accidents.

[0045] Furthermore, in this embodiment, the slider 7 drives the mounting plate 5 to move on the slide rail 6, which can be easily connected with the transition cylinder 1, and the mounting plate 5 can also be easily removed to clean or replace the fiber optic sensor transmitter 2 and fiber optic sensor receiver 3 on the mounting plate 5.

[0046] Example 2 Based on the mixing machine batching supply status detection device provided in Embodiment 1, this embodiment provides a mixing machine batching supply status detection method, such as... Figure 8 As shown, the method includes the following steps: Step 101: Set the light reception threshold for the fiber optic sensor receiver 3. When the light reception at the fiber optic sensor receiver 3 is greater than this threshold, the processing module generates a first-level output signal, indicating no material obstruction. When the light reception at the fiber optic sensor receiver 3 is less than this threshold, the processing module generates a second-level output signal, indicating material obstruction. In this step, a suitable initial light reception threshold needs to be set for the fiber optic sensor. When the light reception is greater than this threshold, it indicates no material is passing through, i.e., no material obstruction; when the light reception is less than this threshold, it indicates material is passing through, i.e., material obstruction. Specifically, because the plastic particle material of each ingredient is different, the light reception when obstruction occurs is also different. Therefore, it is necessary to conduct prior experiments for each different ingredient to obtain a suitable critical point between obstruction and non-obstruction, and then set this critical point as the initial light reception threshold to ensure the sensor works normally.

[0047] Step 102: Connect the output signal of the processing module to the controller. After the batching starts, obtain the controller's scan cycle t. In each scan cycle, determine the state of the output signal. If the output signal is at the second level, then t... n =t n-1 +t. Where t n t represents the total time during the batching process when materials obstruct the flow. n-1 Let t be the total time during the previous scan cycle when material obstruction occurred, and n be the total number of scan cycles during the batching process when material obstruction occurred. Specifically, the sensor's output signal can be connected to a controller, typically a Programmable Logic Controller (PLC), but other types are also possible. The controller monitors the batching start signal. After batching starts, it monitors the sensor's output signal, acquires the controller's scan cycle, and determines the output signal status in each scan cycle. Assuming the sensor outputs a high level (first level) when there is no obstruction, and a low level (second level) when there is obstruction, the total time the second level occurs during the batching process is counted, which is the total time during the batching process when material obstruction occurs. n .

[0048] Step 103: Set the comparison time T1. If the time t during the batching process... nIf the comparison time T1 is greater than T1, the material supply status is determined to be normal; otherwise, the material supply status is determined to be abnormal, and an alarm is issued. In this step, the comparison time T1 can be preset, and the specific T1 value needs to be determined through experiments with different material batches. In principle, the comparison time T1 is the minimum time it takes for material to pass through the sensor when the material supply status is normal. Therefore, if t... n T1 indicates that the material supply is normal; otherwise, it means that less material has passed through the sensor than should have, which means that the material supply is abnormal. This may be due to issues such as material clumping or blockage. A warning will then be issued so that the operator can understand and resolve the problem in a timely manner.

[0049] The above technical solution can determine whether the material supply status is normal, thereby enabling timely detection of abnormal material supply during the production process and avoiding batch quality accidents.

[0050] Based on the above detection methods, a method for detecting abnormal operation of fiber optic sensors is also provided below, so as to detect abnormal operation of fiber optic sensors in a timely manner, and then manually clean the dust or replace the sensor.

[0051] refer to Figure 9 As shown, the fiber optic sensor malfunction detection method includes the following steps: Step 201: After the feeding stops, the output signal status is checked once in each scan cycle. If the output signal is at the second level, then t m =t m-1 +t. Where t m t represents the total time during which materials obstruct the feed during the feeding stop process. m-1 t represents the total time during the previous scan cycle when material obstruction occurred, and m represents the total number of scan cycles during the dispensing stoppage when material obstruction occurred. It should be noted that after dispensing stops, aside from a small amount of plastic particles still rolling off due to inertia, the sensor signal should not be obstructed for the vast majority of the time. Therefore, the sensor output signal is continuously monitored, and the signal state is determined once per scan cycle. The total time during the dispensing stoppage when the second level appears is counted, which is the total time t during the dispensing stoppage when material obstruction occurred. m .

[0052] Step 202: Set the comparison time T2. If the batching process stops, t m If the comparison time T2 is greater than 2, the fiber optic sensor is deemed to be malfunctioning, and an alarm is issued. In this step, the comparison time T2 can be preset, but the specific value of T2 needs to be determined experimentally based on different feed ratios. In principle, the comparison time T2 is the maximum time that material passes through the sensor after the feeding stops. Therefore, if t is the end of the feeding process... mA value of T2 indicates that the sensor detected an abnormally long period of obstruction. This could be due to dust obstructing the sensor to a degree that affects its judgment, or the sensor itself being damaged. This leads to the conclusion that the fiber optic sensor is malfunctioning and triggers an alarm. Upon inspection, if the sensor is simply obstructed by dust, it will be cleaned; if the sensor is damaged, it will be replaced.

[0053] The above technical solution can determine whether the fiber optic sensor is malfunctioning. If it is, it will automatically alarm to remind the operator to replace or clean the fiber optic sensor.

[0054] Based on the above detection method, in order to ensure that the fiber optic sensor can still work normally within a certain range of dust accumulation, instead of triggering an alarm as soon as there is a little dust obstruction, this application embodiment also provides a method that can adaptively adjust the light intensity according to the decrease in light received, so as to improve the service life of the fiber optic sensor and reduce the number of times the sensor needs to be manually cleaned.

[0055] refer to Figure 10 and Figure 11 As shown, the method for adaptively adjusting light intensity based on a decrease in received light includes the following steps: Step 301: During initial operation, the light intensity of the fiber optic sensor transmitter 2 is set to a low value, lux_s_1. Based on this, the light reception threshold lux_thr of the fiber optic sensor receiver 3 is determined. At this point, the light reception of the fiber optic sensor receiver 3 without material obstruction is lux_p, and a preset light reception warning value lux_p_lim is set. The initial low light intensity lux_s_1 is to allow for subsequent strengthening of the light intensity, ensuring sufficient light reception even when the fiber optic sensor is obstructed by dust, thereby extending the lifespan of the fiber optic sensor and reducing the frequency of cleaning.

[0056] Step 302: When the light received at the fiber optic sensor receiver 3 drops below the preset light received amount warning value lux_p_lim when there is no material obstruction, the light intensity at the fiber optic sensor transmitter 2 is adjusted upwards to restore the light received at the fiber optic sensor receiver 3 to lux_p. The light received amount warning value lux_p_lim needs to be greater than the light received amount threshold lux_thr, but less than the initial light received amount when there is no material obstruction, which is lux_p. In this way, the process of adjusting the light intensity according to the light received amount warning value lux_p_lim will not interfere with the judgment of whether there is material obstruction.

[0057] Step 303: After multiple adjustments, the light intensity at the fiber optic sensor transmitter 2 reaches its upper limit. Then, when the light received at the fiber optic sensor receiver 3 drops to the light received threshold lux_thr, an automatic alarm is triggered. After multiple adjustments in step 302, the light intensity at the fiber optic sensor transmitter 2 increases from the initial lux_s_1 to lux_s_2, lux_s_3...lux_s_n, reaching its upper limit and then unable to increase further. Dust continues to accumulate on the sensor until the light received at the fiber optic sensor receiver 3 drops below the light received threshold lux_thr. The sensor then malfunctions and automatically alarms, prompting staff to clean it.

[0058] The above technical solution can automatically adjust the relevant parameters of the fiber optic sensor regarding light intensity, thereby making full use of the performance of the fiber optic sensor and reducing the number of times the fiber optic sensor needs to be manually cleaned.

[0059] Based on the above detection method, in order to ensure that the fiber optic sensor can still work normally within a certain range of dust accumulation, instead of alarming as soon as there is a little dust obstruction, this application embodiment also provides a method that can adaptively adjust the light reception threshold and light reception warning value according to the decrease in light reception, so as to improve the service life of the fiber optic sensor and reduce the number of times the sensor needs to be cleaned manually.

[0060] refer to Figure 12 and Figure 13 As shown, the method for adaptively adjusting the light reception threshold and light reception warning value based on the decrease in light reception includes the following steps: Step 401: During initial operation, set the light intensity of the fiber optic sensor transmitter 2 to the maximum value lux_s_max, and based on this, adjust the light reception threshold lux_thr_1 of the fiber optic sensor receiver 3. At this point, the light reception of the fiber optic sensor receiver 3 without material obstruction is lux_p, and the preset light reception warning value is lux_p_lim_1. Setting the initial light intensity to the maximum value lux_s_max allows for subsequent reduction of the light reception threshold and warning value, ensuring sufficient light reception even when the fiber optic sensor is obstructed by dust, thereby extending the sensor's lifespan and reducing cleaning frequency.

[0061] Step 402: When the light received by the fiber optic sensor receiver 3 drops below the preset light received warning value lux_p_lim_1 when there is no material obstruction, adjust the light received threshold of the fiber optic sensor receiver 3 to lux_thr_2 and adjust the light received warning value to lux_p_lim_2 according to a certain ratio. The light received warning value needs to be kept greater than the light received threshold and less than the initial light received value lux_p when there is no material obstruction, so that the adjustment process will not interfere with the judgment of whether there is material obstruction.

[0062] Step 403: After multiple adjustments, the light reception threshold of the fiber optic sensor receiver 3 automatically alarms when it reaches the lower limit. After multiple adjustments in step 402, the light reception threshold is adjusted from the initial lux_thr_1 to lux_thr_2, lux_thr_3...lux_thr_n, and the light reception warning value is also proportionally adjusted from the initial lux_p_lim_1 to lux_p_lim_2, lux_p_lim_3...lux_p_lim_n. Furthermore, once the light reception threshold reaches the lower limit, it cannot be lowered further. Afterwards, dust on the sensor continues to accumulate, and the light reception decreases until the fiber optic sensor malfunctions and automatically alarms, prompting staff to clean it.

[0063] The above technical solution can automatically adjust the relevant parameters of the fiber optic sensor regarding the light reception threshold, thereby making full use of the performance of the fiber optic sensor and reducing the number of times the fiber optic sensor needs to be manually cleaned.

[0064] In summary, the embodiments of this application can determine whether the material supply status is normal, detect abnormal operation of the fiber optic sensor, and automatically adjust the relevant parameters of the fiber optic sensor regarding light intensity and light reception threshold, thereby making full use of the performance of the fiber optic sensor and reducing the number of times the fiber optic sensor needs to be manually cleaned.

[0065] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A material supply status detection device for a mixing machine, characterized in that, The system includes a transition cylinder (1) for connecting the dispensing cylinder (100) and the buffer cylinder (200), and an optical fiber sensor disposed at the transition cylinder (1). The optical fiber sensor includes a processing module and an optical fiber sensor transmitter (2) and an optical fiber sensor receiver (3) connected to the processing module; wherein: The fiber optic sensor transmitter (2) and the fiber optic sensor receiver (3) are located on opposite sides of the transition cylinder (1). The part of the fiber optic sensor transmitter (2) used to transmit optical signals and the part of the fiber optic sensor receiver (3) used to receive optical signals are both located inside the transition cylinder (1).

2. The mixing machine batching supply status detection device according to claim 1, characterized in that, A base (4) is provided on one side of the transition cylinder (1), and mounting plates (5) are provided on both sides of the transition cylinder (1) on the base (4). The fiber optic sensor transmitter (2) is mounted on the mounting plate (5) on one side, and the fiber optic sensor receiver (3) is mounted on the mounting plate (5) on the other side.

3. The mixing machine batching supply status detection device according to claim 2, characterized in that, The transition cylinder (1) has a cut (101) at a position corresponding to the mounting plate (5), and the shape of the cut (101) matches the shape of the mounting plate (5) facing the transition cylinder (1); the mounting plate (5) has a through groove (501), and the part of the fiber optic sensor transmitting end (2) used to transmit optical signals and the part of the fiber optic sensor receiving end (3) used to receive optical signals enter the interior of the transition cylinder (1) through the through groove (501).

4. The mixing machine batching supply status detection device according to claim 2, characterized in that, The base (4) is provided with slide rails (6) on both sides, and sliders (7) are provided on the slide rails (6). The mounting plate (5) is fixed on the sliders (7).

5. The mixing machine batching supply status detection device according to any one of claims 1-4, characterized in that, The transition cylinder (1) is provided with at least two compressed air nozzles (8), one of which is aligned with the part of the optical fiber sensor transmitter (2) used to transmit optical signals, and the other is aligned with the part of the optical fiber sensor receiver (3) used to receive optical signals.

6. The mixing machine batching supply status detection device according to any one of claims 1-4, characterized in that, The transition cylinder (1) is installed at an angle between the batching cylinder (100) and the buffer cylinder (200), and the end of the transition cylinder (1) connected to the batching cylinder (100) is higher than the end connected to the buffer cylinder (200).

7. A method for detecting the feeding status of a mixer, applied to the mixing feed status detection device of any one of claims 1-6, characterized in that, include: Set the light reception threshold of the fiber optic sensor receiver (3). When the light reception of the fiber optic sensor receiver (3) is greater than the light reception threshold, the processing module generates a first-level output signal and determines that there is no material blocking it. When the amount of light received by the fiber optic sensor receiver (3) is less than the light received threshold, the processing module generates a second-level output signal to determine that there is material blocking it. The output signal of the processing module is connected to the controller. After the batching process starts, the controller's scan cycle t is obtained. The state of the output signal is checked once in each scan cycle. If the output signal is at the second level, then t... n =t n-1 +t; where t n t represents the total time during the batching process when materials obstruct the flow. n-1 is the total time that the material obscures the material during the previous scan cycle, and n is the total number of scan cycles that the material obscures the material during the batching process; Set the comparison time T1, if t during the batching process n If the value is >T1, the material supply status is determined to be normal; otherwise, the material supply status is determined to be abnormal, and an alarm is issued.

8. The method for detecting the material supply status of a mixer according to claim 7, characterized in that, Includes: After the feeding process stops, the output signal status is checked once per scan cycle. If the output signal is at the second level, then t m =t m-1 +t; where t m t represents the total time during which materials obstruct the feed during the feeding stop process. m-1 is the total time during the previous scan cycle when there was material obstruction, and m is the total number of scan cycles during the feeding stop process when there was material obstruction; Set the comparison time T2. If the batching process stops, t m If T2 is detected, the fiber optic sensor is deemed to be malfunctioning, and an alarm is issued.

9. The method for detecting the material supply status of a mixer according to claim 7 or 8, characterized in that, include: When the initial operation is started, the light intensity of the fiber optic sensor transmitter (2) is set to a low value lux_s_1, and the light reception threshold lux_thr of the fiber optic sensor receiver (3) is adjusted on this basis. At this time, the light reception of the fiber optic sensor receiver (3) when there is no material blocking it is lux_p, and the preset light reception warning value lux_p_lim is . When the light received by the fiber optic sensor receiver (3) drops below the preset light received warning value lux_p_lim when there is no material obstruction, the light intensity of the fiber optic sensor transmitter (2) is adjusted upward so that the light received by the fiber optic sensor receiver (3) is restored to lux_p. After multiple adjustments, the light intensity of the fiber optic sensor transmitter (2) reaches its upper limit. Then, when the light received by the fiber optic sensor receiver (3) drops to the light received threshold lux_thr, an automatic alarm is triggered.

10. The method for detecting the material supply status of a mixer according to claim 7 or 8, characterized in that, include: When the initial operation is started, the light intensity of the fiber optic sensor transmitter (2) is set to the maximum value lux_s_max, and the light reception threshold lux_thr_1 of the fiber optic sensor receiver (3) is adjusted based on this. At this time, the light reception of the fiber optic sensor receiver (3) when there is no material blocking it is lux_p, and the preset light reception warning value lux_p_lim_1 is lux_p_lim_1. When the light received by the fiber optic sensor receiver (3) drops below the preset light received warning value lux_p_lim_1 when there is no material obstruction, the light received threshold of the fiber optic sensor receiver (3) is adjusted to lux_thr_2 and the light received warning value is adjusted to lux_p_lim_2 according to a certain ratio. After multiple adjustments, the light reception threshold of the fiber optic sensor receiver (3) reaches the lower limit and an alarm is automatically triggered.

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