Digital monitoring system of full-automatic casting machine

Abstract

The invention discloses a digital monitoring system of a full-automatic casting machine, and relates to the technical field of auxiliary control systems of casting machines, and the digital monitoring system comprises an operation mechanism control module which is used for autonomously controlling all mechanism parts in the full-automatic casting machine so as to achieve the purpose of automatic operation. According to the digital monitoring system of the full-automatic casting machine, the fault early warning judgment module and the fault strength judgment module are arranged, so that the digital monitoring system can automatically judge according to collected data and a set parameter range, and whether a fault occurs or not and the fault strength are automatically judged; meanwhile, an instruction is sent to the corresponding module for corresponding processing according to the judgment information, and the fault early warning judgment module carries out early warning judgment from three aspects of threshold early warning, trend early warning and correlation early warning, so that the accuracy of fault early warning judgment is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of auxiliary control systems for casting machines, specifically a digital monitoring system for a fully automatic casting machine. Background Technology

[0002] A fully automatic casting machine is a high-precision device that uses automated control technology to continuously form thin films and sheets. Its core function is to uniformly coat liquid slurry (such as polymer solutions, ceramic slurries, metal slurries, etc.) onto a carrier, and after drying and curing, form a film or sheet of uniform thickness. It is widely used in electronics, new energy, packaging, pharmaceuticals and other fields. Its "fully automatic" nature is reflected in the fact that the entire process from raw material transportation and coating to finished product winding does not require manual intervention, and parameters can be adjusted in real time through a digital system to ensure product consistency. In order to improve the degree of automation and operational safety of the casting machine, a data monitoring system is needed to monitor and process the operation of the fully automatic casting machine to ensure that each mechanism is more stable and safe during operation.

[0003] Furthermore, the existing digital monitoring system has poor fault warning and fault intensity discrimination performance, which means that any fault that occurs during the operation of the casting machine can only be handled manually. Some minor faults (such as large difference in the running speed of the front and rear mechanisms, rising operating temperature of the mechanism, excessive humidity inside the equipment, etc.) cannot be automatically controlled, thereby reducing the automation level of the casting machine and increasing the maintenance frequency of the technicians. Summary of the Invention

[0004] The purpose of this invention is to provide a digital monitoring system for a fully automated casting machine to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a digital monitoring system for a fully automated casting machine, comprising:

[0006] The operating mechanism control module is used to autonomously control the various components within the fully automatic casting machine to achieve automated operation.

[0007] The operation data acquisition module is used to collect the operation data of each mechanism and component in the fully automatic casting machine in real time, and to preprocess the collected data for subsequent fault diagnosis and processing.

[0008] The parameter setting module consists of multiple parameter setting units, allowing users to set various threshold ranges according to the operational requirements of the product and equipment, so that the system can perform automatic fault warning processing in the future.

[0009] A data repository is used to store and record fault handling data and different membrane material parameter setting data, so that subsequent staff and systems can directly retrieve and use them to achieve the purpose of quickly troubleshooting.

[0010] The fault early warning and judgment module automatically receives data transmitted by the running data acquisition module and performs automatic fault judgment based on the threshold set in the data storage repository, and automatically transmits the judgment information to the subsequent modules for processing.

[0011] The fault intensity determination module is used to automatically determine the fault intensity information, thereby automatically distinguishing whether the fault information needs to be notified to the maintenance engineer for maintenance or whether the auxiliary mechanism needs to be activated for automatic adjustment, such as temperature imbalance, humidity imbalance, etc.

[0012] An alarm control module is used to control the alarm to sound an alarm, and to control the corresponding alarm to sound an alarm according to the location of the fault, so that the maintenance technician can find the fault location in time and carry out efficient maintenance.

[0013] The fault analysis and auxiliary processing module is used to assist in analyzing the cause of the fault and provide the optimal processing solution based on the past targeted fault processing solutions stored in the data repository, so that the repair technician can handle it quickly. At the same time, the latest fault problems will be automatically collected and stored in the data repository for subsequent automatic retrieval.

[0014] Furthermore, the operating mechanism control module includes a temperature and humidity control unit, a feeding mechanism control unit, a processing mechanism control unit, and a discharging mechanism control unit. The temperature and humidity control unit is used to control the cooling, heating, and dehumidification mechanisms inside the casting machine, so that the operating mechanism control module can automatically control the operation of the corresponding mechanism to troubleshoot when it receives an instruction. The feeding mechanism control unit is used to control the operating speed of the screw pump, thereby dynamically adjusting the material supply according to the casting speed to ensure the smooth operation of the casting machine. The processing mechanism control unit is used to control the scraper mechanism, base belt conveying mechanism, and drying and curing mechanism inside the casting machine, and to make them form a fully automatic flow operation according to the preset operating program. At the same time, the discharging mechanism control unit is used to control the peeling angle and winding speed of the peeling mechanism and the winding mechanism, which ensures that the film is not easily torn when the casting machine peels the film, and also ensures that the roll is tight and wrinkle-free, ensuring that the film edges are aligned for subsequent packaging processing.

[0015] Furthermore, the operational data acquisition module includes a data acquisition unit, a data standardization processing unit, and a data transmission unit. The output of the data acquisition unit is connected to the input of the data standardization processing unit, and the output of the data standardization processing unit is connected to the input of the data transmission unit. The data standardization processing unit is used to filter, reduce noise, and normalize the raw data acquired by the data acquisition unit, thereby eliminating interference signals (such as abnormal values ​​caused by instantaneous voltage fluctuations).

[0016] Furthermore, the data acquisition unit employs various types of sensors for real-time data acquisition and processing, such as infrared sensors, online refractometers, rotational viscometers, ultrasonic sensors, encoders, laser displacement sensors, tension sensors, and capacitive humidity sensors. The sensors must completely cover all core components of the equipment (such as take-up rollers, stripping rollers, slurry storage tanks, and conveying pumps) to ensure the accuracy and comprehensiveness of the data.

[0017] Furthermore, the fault early warning and discrimination module includes threshold early warning, trend early warning, and correlation early warning. Threshold early warning: Based on the preset safety threshold of key parameters in the parameter setting module (such as the temperature of the slurry, solid content, viscosity, bubble content, casting speed, doctor blade gap, baseband tension, winding tension, etc.), an "early warning" is triggered when the monitored value approaches the threshold, and an "alarm" is triggered when it exceeds the threshold. Trend early warning: By analyzing the trend of data changes through machine learning models (such as time series analysis, LSTM neural network), hidden faults that "slowly deviate from the normal range" are identified (such as the vibration value increasing month by month due to bearing wear). Correlation early warning: Combining the correlation of multiple parameters (such as "change in winding tension + change in film peeling angle" may indicate that the film is tearing), thereby avoiding misjudgment based on a single parameter.

[0018] Furthermore, the parameter setting module includes a film material size setting unit and a production environment setting unit, and the film material size setting unit includes a width range setting unit and a thickness range setting unit, so as to determine that when the film material detected by the sensor exceeds the set range value, an alarm warning can be issued in a timely manner.

[0019] Furthermore, the production environment setting unit includes a temperature range setting unit, a humidity range setting unit, a vibration frequency setting unit, and a winding tension setting unit, thereby providing threshold ranges and a basis for judgment for the subsequent fault early warning and fault intensity judgment modules.

[0020] Furthermore, the fault analysis auxiliary processing module includes a fault record receiving unit, a fault comparison and discrimination unit, a historical processing scheme recording unit, an automatic data backtracking unit, and a fault record collection unit. The fault record receiving unit is used to automatically receive the detected serious fault information that requires maintenance, and the fault comparison and discrimination unit is used to automatically compare whether the received fault information is the same as the fault information records stored in the data storage repository, and display the corresponding data according to the discrimination content so that the maintenance engineer can browse it, thereby achieving the purpose of assisting fault handling.

[0021] Furthermore, the historical processing record is used to automatically provide the same fault handling solutions from the past, thereby improving both the speed of troubleshooting by the repairman and the accuracy of the fault handling solutions.

[0022] Furthermore, the output of the automatic data backtracking is connected to the input of the fault record collection unit, and the automatic data backtracking is used to automatically retrieve historical data (such as sensor curves and operation logs) within half an hour before the fault, thereby assisting the repair technician in verifying the diagnostic conclusions. The fault record collection unit is used to automatically record fault information and handling solutions so that the optimal solution can be automatically provided when the same fault is detected in the future.

[0023] This invention provides a digital monitoring system for a fully automated casting machine, which has the following advantages:

[0024] 1. This invention, through the establishment of a fault early warning and fault intensity judgment module, enables the data monitoring system to automatically judge based on the collected data and the set parameter range, thereby automatically determining whether a fault has occurred and its intensity. Simultaneously, it sends instructions to the corresponding modules for processing based on the judgment information. Furthermore, because the fault early warning and judgment module performs early warning judgment from three aspects—threshold early warning, trend early warning, and correlation early warning—it greatly improves the accuracy of fault early warning judgment. Moreover, through the setting of the operating mechanism control module, it enables automatic handling of minor faults in the casting machine (such as temperature or humidity exceeding thresholds, or winding tension peeling angle exceeding set values), thereby reducing the maintenance frequency of technicians and improving the fully automated performance of the casting machine.

[0025] 2. This invention, through its fault analysis and auxiliary processing module, enables the data-driven monitoring system to automatically compare and process past fault handling information stored in the data repository when it detects a fault in the casting machine that cannot be automatically handled. If there are past records in the data repository, maintenance information will be automatically provided so that the maintenance technician can quickly and specifically handle the problem. If there are no records in the data repository, half an hour of machine operation data will be automatically provided so that the maintenance technician can quickly verify the diagnosis. This greatly improves the speed of troubleshooting for the maintenance technician. Furthermore, the fault analysis and auxiliary processing module will also include the latest processing solutions in the data repository so that the system can automatically retrieve them later, enabling the maintenance technician to troubleshoot the same problem more quickly in the future. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall operation flow of a digital monitoring system for a fully automatic casting machine according to the present invention;

[0027] Figure 2 This is a schematic diagram of the operation flow of the control module of the digital monitoring system for a fully automatic casting machine according to the present invention.

[0028] Figure 3 This is a schematic diagram of the operation flow of the operation data acquisition module of the digital monitoring system for a fully automatic casting machine according to the present invention;

[0029] Figure 4 This is a schematic diagram of the operation flow of the parameter setting module of the digital monitoring system for a fully automatic casting machine according to the present invention;

[0030] Figure 5 This is a schematic diagram of the operation flow of the fault analysis and auxiliary processing module of the digital monitoring system for a fully automatic casting machine according to the present invention. Detailed Implementation

[0031] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0032] like Figures 1-5 As shown, a digital monitoring system for a fully automated casting machine includes:

[0033] The operating mechanism control module is used to autonomously control various components within the fully automatic casting machine to achieve automated operation. This module includes a temperature and humidity control unit, a feeding mechanism control unit, a processing mechanism control unit, and a discharging mechanism control unit. The temperature and humidity control unit controls the cooling, heating, and dehumidification mechanisms inside the casting machine, enabling the operating mechanism control module to automatically control the corresponding mechanisms to troubleshoot problems upon receiving instructions. The feeding mechanism control unit controls the operating speed of the screw pump, thereby dynamically adjusting the material supply based on the casting speed to ensure smooth operation of the entire casting machine. The system is designed to ensure smooth operation. The processing mechanism control unit controls the scraper mechanism, base belt conveying mechanism, and drying and curing mechanism inside the casting machine, and enables them to operate in a fully automatic, continuous manner according to the preset operating program. At the same time, the feeding mechanism control unit controls the peeling angle and winding speed of the peeling mechanism and the winding mechanism. This ensures that the film is not easily torn when the casting machine peels the film, and also ensures that the roll is tight and wrinkle-free, guaranteeing that the film edges are aligned for subsequent packaging. Through the set control units of each mechanism, the operating mechanism control module can automatically adjust the operating speed and open / close of each mechanism when it receives instructions, thereby achieving the purpose of automatically handling minor faults and controlling the automatic operation of the casting machine.

[0034] The system includes a data acquisition module for real-time acquisition of operational data from various components within the fully automatic casting machine. This data is pre-processed for subsequent fault diagnosis. The module comprises a data acquisition unit, a data standardization processing unit, and a data transmission unit. The output of the data acquisition unit is connected to the input of the data standardization processing unit. The data acquisition unit employs various types of sensors for real-time data acquisition and processing, such as infrared sensors, online refractometers, rotational viscometers, ultrasonic sensors, encoders, laser displacement sensors, tension sensors, and capacitive humidity sensors. The sensors must completely cover all core components of the equipment (such as winding rollers, stripping rollers, slurry tanks, and conveying pumps) to ensure data accuracy and comprehensiveness. The output of the data standardization processing unit is connected to the input of the data transmission unit. This unit filters, reduces noise, and normalizes the raw data acquired by the data acquisition unit, eliminating interference signals (such as outliers caused by instantaneous voltage fluctuations). This ensures the accuracy of the judgment information during subsequent judgment by the fault diagnosis module and improves the precision of data identification by the fault diagnosis module.

[0035] The parameter setting module consists of multiple parameter setting units, allowing users to set various threshold ranges according to the needs of product and equipment operation. This enables the subsequent system to perform automatic fault warning processing. The parameter setting module includes a film size setting unit and a production environment setting unit. The film size setting unit includes a width range setting unit and a thickness range setting unit, which ensures that an alarm can be issued in a timely manner when the film detected by the sensor exceeds the set range value. The production environment setting unit includes a temperature range setting unit, a humidity range setting unit, a vibration frequency setting unit, and a winding tension setting unit, which provides threshold ranges and a basis for judgment for the subsequent fault warning and fault intensity judgment modules, so that operators can set the safety thresholds of various mechanisms during the operation of the casting machine.

[0036] A data repository is used to store and record fault handling data and different membrane material parameter setting data, so that subsequent staff and systems can directly retrieve and use them to achieve the purpose of quickly troubleshooting.

[0037] The fault early warning and discrimination module automatically receives data transmitted from the running data acquisition module and performs automatic fault discrimination based on the thresholds set in the data storage repository. The discrimination information is then automatically transmitted to subsequent modules for processing. The fault early warning and discrimination module includes threshold early warning, trend early warning, and correlation early warning. Threshold early warning: Based on preset safety thresholds for key parameters (such as slurry temperature, solid content, viscosity, bubble content, casting speed, scraper gap, baseband tension, and winding tension) in the parameter setting module, an "early warning" is triggered when the monitored value approaches the threshold, and an "alarm" is triggered when it exceeds the threshold. Trend early warning: Data change trends are analyzed using machine learning models (such as time series analysis and LSTM neural networks) to identify latent faults that "slowly deviate from the normal range" (such as a monthly increase in vibration values ​​caused by bearing wear). Correlation early warning: Multiple parameter correlations are combined (such as "change in winding tension + change in film peeling angle" may indicate film tearing), thereby avoiding misjudgment based on a single parameter.

[0038] The fault intensity determination module is used to automatically determine the fault intensity information, thereby automatically distinguishing whether the fault information needs to be notified to the maintenance engineer for maintenance or whether the auxiliary mechanism needs to be activated for automatic adjustment, such as temperature imbalance, humidity imbalance, etc.

[0039] An alarm control module is used to control the alarm to sound an alarm, and to control the corresponding alarm to sound an alarm according to the location of the fault, so that the maintenance technician can find the fault location in time and carry out efficient maintenance.

[0040] The fault analysis and auxiliary processing module assists in analyzing the causes of faults and provides optimal solutions based on past targeted fault handling plans stored in the data repository, enabling technicians to handle them quickly. It also automatically records and stores the latest faults in the data repository for later automatic retrieval. The module includes a fault record receiving unit, a fault comparison and discrimination unit, a historical handling plan record, automatic data backtracking, and a fault record collection unit. The fault record receiving unit automatically receives critical fault information requiring repair, and the fault comparison and discrimination unit automatically compares the received fault information with the data stored in the data repository. The system checks whether fault information records are identical and displays corresponding data based on the judgment content for technicians to browse, thereby assisting in fault handling. Historical handling plan records are used to automatically provide handling plans for the same faults in the past, which improves both the speed and accuracy of the technicians' troubleshooting. The output of the automatic data backtracking is connected to the input of the fault record collection unit, and the automatic data backtracking is used to automatically retrieve historical data (such as sensor curves and operation logs) within half an hour before the fault, thereby assisting technicians in verifying diagnostic conclusions. The fault record collection unit is used to automatically record fault information and handling plans so that the optimal solution can be automatically provided when the same fault is detected later.

[0041] The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and to design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A digital monitoring system for a fully automated casting machine, characterized in that, include: The operating mechanism control module is used to autonomously control the various components within the fully automatic casting machine to achieve automated operation. The operation data acquisition module is used to collect the operation data of each mechanism and component in the fully automatic casting machine in real time, and to preprocess the collected data for subsequent fault diagnosis and processing. The parameter setting module consists of multiple parameter setting units, allowing users to set various threshold ranges according to the operational requirements of the product and equipment, so that the system can perform automatic fault warning processing in the future. A data repository is used to store and record fault handling data and different membrane material parameter setting data, so that subsequent staff and systems can directly retrieve and use them to achieve the purpose of quickly troubleshooting. The fault early warning and judgment module automatically receives data transmitted by the running data acquisition module and performs automatic fault judgment based on the threshold set in the data storage repository, and automatically transmits the judgment information to the subsequent modules for processing. The fault intensity determination module is used to automatically determine the fault intensity information, thereby automatically distinguishing whether the fault information needs to be notified to the maintenance engineer for maintenance or whether the auxiliary mechanism needs to be activated for automatic adjustment, such as temperature imbalance, humidity imbalance, etc. An alarm control module is used to control the alarm to sound an alarm, and to control the corresponding alarm to sound an alarm according to the location of the fault, so that the maintenance technician can find the fault location in time and carry out efficient maintenance. The fault analysis and auxiliary processing module is used to assist in analyzing the cause of the fault and provide the optimal processing solution based on the past targeted fault processing solutions stored in the data repository, so that the repair technician can handle it quickly. At the same time, the latest fault problems will be automatically collected and stored in the data repository for subsequent automatic retrieval.

2. The digital monitoring system for a fully automatic casting machine according to claim 1, characterized in that, The operating mechanism control module includes a temperature and humidity control unit, a feeding mechanism control unit, a processing mechanism control unit, and a discharging mechanism control unit. The temperature and humidity control unit controls the cooling, heating, and dehumidification mechanisms inside the casting machine, so that the operating mechanism control module can automatically control the corresponding mechanisms to troubleshoot when it receives instructions. The feeding mechanism control unit controls the operating speed of the screw pump, thereby dynamically adjusting the material supply according to the casting speed to ensure the smooth operation of the casting machine. The processing mechanism control unit controls the scraper mechanism, base belt conveying mechanism, and drying and curing mechanism inside the casting machine, and makes them operate in a fully automatic flow according to a preset operating program. At the same time, the discharging mechanism control unit controls the peeling angle and winding speed of the peeling mechanism and the winding mechanism, which ensures that the film is not easily torn when the casting machine peels the film, and also ensures that the roll is tight and wrinkle-free, ensuring that the film edges are aligned for subsequent packaging.

3. The digital monitoring system for a fully automatic casting machine according to claim 1, characterized in that, The operational data acquisition module includes a data acquisition unit, a data standardization processing unit, and a data transmission unit. The output of the data acquisition unit is connected to the input of the data standardization processing unit, and the output of the data standardization processing unit is connected to the input of the data transmission unit. The data standardization processing unit is used to filter, reduce noise, and normalize the raw data acquired by the data acquisition unit, thereby eliminating interference signals.

4. The digital monitoring system for a fully automatic casting machine according to claim 3, characterized in that, The data acquisition unit uses various types of sensors for real-time data acquisition and processing, such as infrared sensors, online refractometers, rotational viscometers, ultrasonic sensors, encoders, laser displacement sensors, tension sensors, and capacitive humidity sensors. The sensors must completely cover all core components of the equipment to ensure the accuracy and comprehensiveness of the data.

5. The digital monitoring system for a fully automatic casting machine according to claim 1, characterized in that, The fault early warning and discrimination module includes threshold early warning, trend early warning and correlation early warning. Threshold early warning: based on the preset safety threshold of key parameters in the parameter setting module, when the monitored value approaches the threshold, an "early warning" is triggered, and when it exceeds the threshold, an "alarm" is triggered. Trend early warning: through machine learning model analysis of data change trends, hidden faults that "slowly deviate from the normal range" are identified. Correlation early warning: by combining the correlation of multiple parameters, misjudgment by a single parameter is avoided.

6. The digital monitoring system for a fully automatic casting machine according to claim 1, characterized in that, The parameter setting module includes a film material size setting unit and a production environment setting unit. The film material size setting unit includes a width range setting unit and a thickness range setting unit, so that when the film material detected by the sensor exceeds the set range value, an alarm warning can be issued in a timely manner.

7. The digital monitoring system for a fully automatic casting machine according to claim 6, characterized in that, The production environment setting unit includes a temperature range setting unit, a humidity range setting unit, a vibration frequency setting unit, and a winding tension setting unit, thereby providing threshold ranges and a basis for judgment for the subsequent fault early warning and fault intensity judgment modules.

8. The digital monitoring system for a fully automatic casting machine according to claim 1, characterized in that, The fault analysis and auxiliary processing module includes a fault record receiving unit, a fault comparison and discrimination unit, a historical processing scheme recording unit, an automatic data backtracking unit, and a fault record collection unit. The fault record receiving unit is used to automatically receive serious fault information that needs to be repaired, and the fault comparison and discrimination unit is used to automatically compare whether the received fault information is the same as the fault information records stored in the data storage repository, and display the corresponding data according to the discrimination content so that the repair technician can browse, thereby achieving the purpose of assisting fault handling.

9. The digital monitoring system for a fully automatic casting machine according to claim 8, characterized in that, The historical processing plan record is used to automatically provide the same fault handling plan from the past, thereby improving both the speed of troubleshooting by the repairman and the accuracy of the fault handling plan.

10. A digital monitoring system for a fully automatic casting machine according to claim 8, characterized in that, The output of the automatic data backtracking is connected to the input of the fault record collection unit. The automatic data backtracking is used to automatically retrieve historical data within half an hour before the fault, thereby assisting the repair technician in verifying the diagnostic conclusion. The fault record collection unit is used to automatically record fault information and handling solutions so that the optimal solution can be automatically provided when the same fault is detected in the future.

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