Intelligent control system and method for cutting double-disc ribbon braiding machine

Abstract

The application relates to the technical field of intelligent control, and discloses an intelligent control system and method for a cutting double-turntable ribbon machine, wherein the method comprises the following steps: collecting and calibrating the rotation angle of the angle encoder of a main turntable to obtain an angle reference value and a first angle interval of each work station action trigger; monitoring ribbon position data according to the angle reference value and performing angle trigger control based on the first angle interval to obtain a work station action completion signal; performing product visual detection based on the work station action completion signal to obtain product quality data; and performing cutting and ribbon sealing linkage control based on the product quality data and the ribbon position data to obtain product processing completion data and calculate a second angle interval of each work station action trigger. The application improves the processing precision, production efficiency and product yield of the equipment, and enhances the stability and flexibility.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intelligent control, and particularly relates to an intelligent control system and method for a cutting double-turntable ribbon machine. BACKGROUND

[0002] Traditional ribbon machines mostly adopt single-turntable structures, and the action coordination of various stations is achieved through simple time sequence control. This control method is difficult to meet the production requirements of high speed and high precision. In actual production processes, due to the lack of accurate angle synchronization control mechanism, the action coordination between various stations often deviates, resulting in problems such as inaccurate product positioning, cutting position deviation, unstable packaging quality, and the like, which seriously affect the production efficiency and product yield. At the same time, the traditional control method lacks effective quality monitoring means, and cannot detect the product state in real time and feed back in time, resulting in defective products flowing into subsequent processes, increasing the production cost, and easily causing belt breakage, material jamming and the like, affecting the continuous operation of the equipment. SUMMARY

[0003] The present application provides an intelligent control system and method for a cutting double-turntable ribbon machine, which improves the processing precision, production efficiency and product yield of the equipment, and enhances the stability and flexibility.

[0004] In a first aspect, the present application provides an intelligent control method for a cutting double-turntable ribbon machine, which comprises the following steps:

[0005] Rotational angle acquisition and calibration are performed on the angle encoder of the main turntable to obtain an angle reference value and a first angle interval for triggering the action of each station;

[0006] The ribbon position data is monitored according to the angle reference value, and angle trigger control is performed based on the first angle interval to obtain a station action completion signal;

[0007] Product visual detection is performed based on the station action completion signal to obtain product quality data;

[0008] Cutting and ribbon sealing linkage control are performed based on the product quality data and the ribbon position data to obtain product processing completion data and calculate a second angle interval for triggering the action of each station.

[0009] In combination with the first aspect, in a first implementation manner of the first aspect of the present application, the rotational angle acquisition and calibration are performed on the angle encoder of the main turntable to obtain an angle reference value and a first angle interval for triggering the action of each station, which comprises the following steps:

[0010] Rotational position acquisition is performed on the main turntable by the angle encoder to obtain real-time angle data;

[0011] The main turntable is calibrated for zero position according to the real-time angle data, and an angle reference value is obtained;

[0012] The picking position of the swing arm motor, the turning starting position of the turning motor, the material receiving position of the distance changing motor and the indexing position of the receiving disc motor are mapped according to the angle reference value, and angle coordinates of each motor station are obtained;

[0013] The first angle interval of each station action trigger is determined according to the angle coordinates of each motor station, and the first angle interval includes the swing arm picking angle interval, the swing arm material releasing angle interval, the turning action angle interval and the distance changing material receiving angle interval.

[0014] In combination with the first aspect, in a second implementation manner of the first aspect of the application, the material tape position data is monitored according to the angle reference value, and angle trigger control is performed based on the first angle interval to obtain a station action completion signal, including:

[0015] The material tape remaining amount of the main material disc and the auxiliary material disc is detected by the optical fiber sensor to obtain a material tape supply state parameter;

[0016] The feeding motor is adjusted for tape pulling speed when the main turntable is in the first angle range according to the angle reference value, and a target position deviation value is calculated;

[0017] The material tape is compensated in left and right directions based on the target position deviation value to obtain actual position coordinates of the material tape;

[0018] The material tape position data is generated based on the material tape supply state parameter and the actual position coordinates of the material tape;

[0019] The swing arm motor, the turning motor, the distance changing motor and the receiving disc motor are controlled for angle trigger based on the first angle interval to obtain a station action completion signal.

[0020] In combination with the first aspect, in a third implementation manner of the first aspect of the application, the material tape position data is generated based on the material tape supply state parameter and the actual position coordinates of the material tape, including:

[0021] The detection signal of the optical fiber sensor is accumulated in time according to the material tape supply state parameter to obtain a material tape shortage duration and a material tape jamming duration;

[0022] The actual feeding length deviation value is calculated by difference between the actual position coordinates of the material tape and a theoretical feeding position, and a compensation trigger signal is generated when the actual feeding length deviation value exceeds a deviation threshold value;

[0023] According to the material belt material shortage duration and the material shortage alarm threshold and the material belt jamming duration and the jamming alarm threshold, abnormality judgment is performed to obtain a material belt supply abnormality identifier;

[0024] According to the compensation trigger signal and the material belt supply abnormality identifier, adjustment is performed on a feeding motor compensation value and an alternating current motor rotating speed to obtain material belt position data.

[0025] In a fourth implementation manner of the first aspect, the angle trigger control is performed on the swing arm motor, the turnover motor, the distance changing motor and the material receiving disc motor based on the first angle interval to obtain a work station action completion signal, including:

[0026] Real-time comparison is performed between a current angle value of the main rotating disc and the first angle interval to obtain a swing arm material taking trigger signal, a turnover starting trigger signal, a distance changing material receiving trigger signal and a material receiving disc index trigger signal;

[0027] According to the swing arm material taking trigger signal, when the main rotating disc reaches a first angle, the swing arm motor is controlled to move from a material taking pre-waiting position to a material taking position and activate a suction nozzle vacuum electromagnetic valve, and when the main rotating disc reaches a second angle, the swing arm motor is controlled to move to a material discharging position and perform a vacuum breaking action to obtain a swing arm action execution state;

[0028] Based on the turnover starting trigger signal, when the main rotating disc is in a second angle range, the turnover motor is controlled to perform work station rotation to obtain a turnover action execution state, and according to the distance changing material receiving trigger signal, when the main rotating disc reaches a third angle, the distance changing motor is controlled to move to a material receiving position, and when the main rotating disc reaches a fourth angle, the distance changing motor is controlled to move to a material discharging position to obtain a distance changing action execution state;

[0029] The swing arm action execution state, the turnover action execution state, the distance changing action execution state and an index completion state of the material receiving disc motor are logically combined to obtain a work station action completion signal.

[0030] In a fifth implementation manner of the first aspect, based on the work station action completion signal, product visual detection is performed to obtain product quality data, including:

[0031] According to the work station action completion signal, when the main rotating disc reaches a fifth angle, a rotating disc CCD is triggered to collect product position and posture images, after a sealing belt action is completed, a sealing belt CCD is triggered to collect a sealing quality image, and before cutting, a cutting front CCD is triggered to collect a material presence / absence discrimination image;

[0032] Feature extraction and template matching are performed on the product position and posture images, the sealing quality image and the material presence / absence discrimination image to obtain product position offset and angle deviation values of the rotating disc work station, sealing completeness parameters of the sealing belt work station and material presence / absence determination results of the cutting front work station.

[0033] Generate product quality data based on the product position offset, the angle deviation value, the sealing integrity parameter and the presence or absence of material determination result.

[0034] In combination with the first aspect, in a sixth implementation manner of the first aspect of the present application, the feature extraction and template matching on the product position and posture image, the packaging quality image and the presence or absence of material discrimination image are performed to obtain the product position offset of the rotating disc station and the angle deviation value, the sealing integrity parameter of the sealing belt station and the presence or absence of material determination result of the cutting station, which includes:

[0035] The product position and posture image is subjected to edge detection and centroid positioning calculation to obtain product contour features, the packaging quality image is subjected to sealing area segmentation and connected domain analysis to obtain sealing area features, and the presence or absence of material discrimination image is subjected to binarization and contour extraction to obtain target contour features;

[0036] The product contour features are matched with a preset product standard template to obtain a position offset pixel value and an angle rotation value, the sealing area features are subjected to similarity calculation with a packaging standard template to obtain a sealing continuity value, and the target contour features are subjected to area comparison with a material piece template to obtain a material piece existence determination value;

[0037] The product position offset is calculated based on the position offset pixel value and a pixel calibration coefficient, the angle deviation value is calculated based on the angle rotation value and an angle correction coefficient, the sealing integrity parameter is calculated based on the sealing continuity value and an integrity threshold value, and the presence or absence of material determination result is obtained based on comparison of the material piece existence determination value and a determination threshold value.

[0038] In combination with the first aspect, in a seventh implementation manner of the first aspect of the present application, the cutting and sealing belt linkage control is performed based on the product quality data and the material belt position data to obtain product processing completion data and a second angle interval of each station action trigger, which includes:

[0039] The cutting parameter is adjusted according to the defective product position mark and yield distribution in the product quality data to obtain a cutting speed target value, and the cutting position is compensated according to the actual position coordinates of the material belt in the material belt position data to obtain a cutting position compensation value;

[0040] The cutting motor is controlled to move to a pre-pressing position of the cutting position to apply a pre-pressing force based on the cutting speed target value and the cutting position compensation value, then the cutting action is completed and cutting back-blowing is triggered to obtain a cutting completion state signal and a cutting position record;

[0041] According to the cutting completion state signal, a sealing mechanism is triggered, and according to the set number of empty front, filling and empty rear, the sealing length is controlled to obtain a packaging completion state signal and packaging parameter record;

[0042] According to the packaging completion state signal, the cutting position record, the packaging parameter record, the whole machine yield in the product quality data and the double-turntable discharging frequency are integrated to obtain product processing completion data;

[0043] Based on the product processing completion data, a second angle interval of each station action trigger is calculated.

[0044] In combination with the first aspect, in an eighth implementation manner of the first aspect of the application, the second angle interval of each station action trigger is calculated based on the product processing completion data, including:

[0045] The good product quantity, the defective product quantity and the processing time stamp in the product processing completion data are subjected to deviation statistics to obtain production performance deviation parameters and defective product distribution data of each station;

[0046] According to the defective product distribution data of each station, fault analysis is performed on the swing arm material taking, the turnover action, the variable-distance material receiving and the cutting and packaging to obtain a target priority sequence;

[0047] Based on the production performance deviation parameters and the target priority sequence, angle compensation is performed to obtain angle adjustment amounts of each station;

[0048] The angle adjustment amounts of each station are superimposed on the first angle interval to generate a second angle interval of each station action trigger.

[0049] Secondly, the application provides an intelligent control system of a cutting double-turntable braiding machine, which comprises:

[0050] A rotation angle acquisition and calibration module is configured to acquire and calibrate the rotation angle of an angle encoder of a main turntable to obtain an angle reference value and a first angle interval of each station action trigger;

[0051] An angle trigger control module is configured to monitor material belt position data according to the angle reference value and perform angle trigger control based on the first angle interval to obtain a station action completion signal;

[0052] A product visual detection module is configured to perform product visual detection based on the station action completion signal to obtain product quality data;

[0053] The cutting and banding linkage control module is used for performing cutting and banding linkage control based on the product quality data and the tape position data, obtaining product processing completion data and calculating a second angle interval of each station action trigger.

[0054] In the technical solution, a unified angle reference value is established by the main rotating disc angle encoder, trigger control of each station based on an accurate angle interval is realized, and cumulative error of traditional time sequence control is eliminated. According to the angle reference value, intelligent tension control and displacement compensation are performed on the double-tape feeding motor, so that the belt breakage and material jamming faults are effectively prevented. The angle trigger mechanism is used to cooperatively control the swing arm motor, the turnover motor, the variable distance motor and the receiving disc motor, so that the accurate synchronization of multi-station actions is ensured. The three-level CCD vision detection system performs omnibearing monitoring on the product position, packaging quality and material state, and detects defective products in time. The accurate linkage of cutting and banding is realized based on the product quality data and the tape position data, and processing parameters are dynamically adjusted. The second angle interval is automatically calculated by analyzing the product processing completion data, the control parameters are optimized according to the production performance deviation, and self-adaptive adjustment is realized. The present application improves the processing precision, production efficiency and product yield of the equipment, and enhances the stability and flexibility.

[0055] Other features and advantages of the present application will be set forth in the descriptions that follow, and in part will be apparent from the descriptions, or can be learned by practice of the present application. The objects and other advantages of the present application will be realized and attained by the structure particularly pointed out in the description and claims of the present application.

[0056] In order to make the above-mentioned objects, features and advantages of the present application more obvious and easy to understand, the following preferred embodiments are specifically described in detail below, and the accompanying drawings are referred to. BRIEF DESCRIPTION OF DRAWINGS

[0057] Figure 1 An embodiment schematic diagram of the intelligent control method of the cutting double-rotating disc ribbon machine in the present application;

[0058] Figure 2 An embodiment schematic diagram of the intelligent control system of the cutting double-rotating disc ribbon machine in the present application. DETAILED DESCRIPTION

[0059] In order to make the objects, technical solutions and advantages of the embodiments of the present application more clear, the technical solutions of the present application will be described clearly and completely below with reference to the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the protection scope of the present application.

[0060] The terms "comprising" and "having" and any variations thereof used in the embodiments of the present application are intended to cover a non-exclusive inclusion. For example, a process, method, system, product or device that includes a list of steps or units is not limited to the listed steps or units, but can optionally further include other steps or units not listed, or can optionally further include other steps or units inherent to such process, method, product or device.

[0061] To facilitate the understanding of the present embodiment, first, a kind of cutting double rotary table braiding machine intelligent control method disclosed in the embodiments of the present application will be introduced in detail. As shown in Figure 1 The intelligent control method of cutting double rotary table braiding machine includes the following steps:

[0062] 101, the angle encoder of the main rotary table is rotated and the angle data is obtained by angle encoder of the main rotary table, and the angle data is obtained by angle encoder of the main rotary table. Angle reference value and first angle interval of each station action trigger are obtained;

[0063] In the present embodiment, the rotary position information of the main rotary table is collected in real time by the angle encoder of the main rotary table, and the rotary position information is converted into angle data, and the absolute angle coordinate system of the main rotary table from 0 to 360 degrees is established in the PLC system. The angle data is written into the special angle register in real time, and the precision is not less than 0.1 degree. After collecting the whole rotation data of the main rotary table, the initial reference point of the rotary table, i.e. the mechanical zero position, is calibrated once automatically, the calibration is completed based on the zero position of the physical limit, the photoelectric sensor or the encoder inside, to identify the starting point of the rotary table full cycle angle, form a unified angle reference value. According to the angle reference value, the key action positions of the swing arm motor, the turnover motor, the variable distance motor and the material receiving disc motor and other execution units are mapped by angle, and each action trigger point is converted into the angle coordinate corresponding to the angle coordinate system of the main rotary table; for example, the material taking position and the material releasing position of the swing arm motor are mapped to the positions of 10 degrees and 270 degrees of the main rotary table rotation, the turnover starting position of the turnover motor is mapped near 85 degrees, the material receiving position of the variable distance motor is set at about 185 degrees, and the index action of the material receiving disc motor is mapped to the angle point synchronized with the product beat. According to the angle coordinates of each motor station, the action trigger interval of each motor station is constructed, and a certain angle tolerance range is set to form a continuous first angle interval, so that each station completes the preset action in the corresponding angle interval. The first angle interval includes the action interval of the swing arm motor from material taking waiting to material taking adsorption, the angle interval from material releasing waiting to material releasing, the starting to terminal angle interval of one rotation of the turnover motor, and the angle window of the material receiving action of the variable distance motor.

[0064] 102, according to the angle reference value, the material belt position data is monitored, and the angle trigger control is carried out based on the first angle interval, to obtain the station action completion signal;

[0065] In this embodiment, the remaining length of the tape on the main tray and the auxiliary tray is continuously monitored by the optical fiber sensor, and the feeding state is collected in real time to form the feeding state parameters including the remaining length of the tape, the feeding continuity, the disc replacement warning signal, etc. At the same time, by using the angle reference value calibrated by the main rotating disc, when the main rotating disc rotates to the preset first angle range, specifically between 10 degrees and 100 degrees, the tape pulling action of the feeding motor is executed. At this time, the running speed of the feeding motor is adaptively adjusted according to the current product beat, and the difference between the current position and the theoretical target position of the feeding motor is calculated in real time to form the target position deviation value. According to the target position deviation value, the bidirectional displacement compensation control mechanism is activated, the left and right offset correction amounts are calculated respectively, and the corresponding compensation path is selected according to the deviation direction, so that the carrier tape position is corrected in the micron level range to form the actual position coordinates of the carrier tape at the current time. After fusion analysis of the actual position coordinates of the carrier tape and the tape feeding state parameters, the tape position data is generated, which dynamically reflects the running state and precision matching condition of the feeding system. Based on the tape position data and the trigger window defined by the first angle interval of the main rotating disc, the angle trigger control of the swing arm motor, the turnover motor, the variable distance motor and the receiving disc motor, etc. is automatically performed at the appropriate angle position, so that all the workstations perform the action according to the angle time sequence. The action completion state of each workstation is detected by TML, TMR and other timing logic instructions and feedback relay signals, and the workstation action completion signal is generated when the preset action flow is detected to be completed.

[0066] 103. Perform product visual detection based on the workstation action completion signal to obtain product quality data;

[0067] In this embodiment, the work station action completion signal is used as the trigger basis for image acquisition timing. When the main turntable rotates to a preset fifth angle position, i.e. a detection window near 450 degrees, the turntable CCD installed at the 450 degree position is triggered to perform image acquisition, obtaining the actual position and attitude image of the current work station product. After the sealing station completes the heat sealing operation, the sealing CCD is driven to start shooting by the action completion signal, and the heat sealing integrity image of the packaging area is acquired for judging the structural stability and heat pressing quality of the seal. Before the product reaches the cutting position, the pre-cutting CCD is triggered by the angle position judgment and control logic linkage to shoot 20 mm in front of the cutting position, and the presence or absence of material discrimination image is acquired to determine whether the carrier tape has material and whether the tape direction is abnormal. Based on the high-performance image processing module, the product position and attitude image, the packaging quality image, and the presence or absence of material discrimination image are analyzed synchronously, the key visual features such as product edge contour, seal shape, and background light spot are extracted by the feature extraction algorithm, and the collected image is compared with the preset qualified image by the multi-level template matching method, and then the plane position offset and angle deviation of the product relative to the standard attitude are identified from the turntable CCD image, the heat sealing integrity parameters including the uniformity of the sealing tape, the fusion integrity of the sealing edge, and the seal ghost phenomenon are calculated from the sealing tape CCD image, and whether the current track has material and whether the direction is normal are identified from the pre-cutting CCD image. The three types of image processing results are integrated to form a multi-dimensional quality evaluation index under the current work station, and a product quality data structure is constructed, including position error value, angle offset, seal qualification state, and presence or absence of material logic judgment.

[0068] 104. Perform cutting and sealing linkage control based on product quality data and tape position data to obtain product processing completion data and calculate the second angle interval of each work station action trigger.

[0069] In this embodiment, the product quality data is analyzed to extract the defective product position markers and the yield distribution characteristics in the current period, and based on this, the stability and precision requirements of the cutting beat under the current running state are evaluated, so as to dynamically adjust the speed target value corresponding to the cutting action; at the same time, the coordinate information reflecting the actual position of the current carrier tape in the tape position data is read, and based on this, the cutting offset correction amount is calculated to obtain the cutting position compensation value for compensating the execution action. Based on the cutting speed target value and the cutting position compensation value, the cutting motor sequentially performs the control action, i.e. drives to the pre-press position above the cutting position and applies a set pre-press force to ensure the flatness of the carrier tape, completes the high-precision cutting process at the adjusted speed and compensation position, and starts the cutting back-blowing gas module to remove debris after the cutting is completed, thereby generating a cutting completion state signal and recording the position coordinates corresponding to the current cutting action. Based on the cutting completion state signal, the sealing mechanism is triggered to enter the packaging phase, and the sealing process dynamically determines the sealing length according to the set front empty, filling, and rear empty quantity in the product specification, and completes the hot-press sealing operation in combination with the heat sealing process parameters, and generates a packaging completion state signal and packaging parameter record data at the end of the action. The packaging completion state signal is used as a trigger source for data integration, and the cutting position record in the current period, the packaging parameter record, the machine yield data recognized by the vision system, and the outfeed frequency statistical value provided by the A and B turntable interaction mechanism are comprehensively summarized and stored as a set of structured product processing completion data. After each period ends, the latest processing completion data is used to modify the originally set first angle interval, and the second angle interval is recalculated. The calculation of the second angle interval considers multiple factors such as processing delay, beat offset, NG distribution trend, and introduces a dynamic fine-tuning strategy to refine and optimize the motor action trigger angle window, so as to improve the response consistency and control accuracy of the entire double-turntable ribbon system under high load and high beat conditions.

[0070] In a specific embodiment, the process of step 101 can specifically include the following steps:

[0071] The rotation position of the main turntable is collected by the angle encoder of the main turntable to obtain real-time angle data;

[0072] The zero position of the main turntable is calibrated according to the real-time angle data to obtain an angle reference value;

[0073] The pickup position of the swing arm motor, the pickup position of the swing arm motor, the pickup position of the swing arm motor, the pickup position of the swing arm motor, and the index position of the pickup disc motor are angle mapped based on the angle reference value to obtain the angle coordinates of each motor station;

[0074] The first angle interval of each motor station action trigger is determined according to the angle coordinates of each motor station, and the first angle interval includes the swing arm material taking angle interval, the swing arm material placing angle interval, the overturning action angle interval and the variable distance material receiving angle interval.

[0075] In this embodiment, the rotation state of the main turntable is continuously monitored by an angle encoder on the main turntable. The angle encoder uses a high-resolution absolute position encoder to achieve continuous data output from 0 to 360 degrees in the full angle range, and the collected raw pulse values are transmitted to the programmable logic controller in real time. After angle conversion calculation, real-time angle data is formed, which is written into a special register in floating-point format and updated periodically with the main control system. According to the real-time angle data, the zero-point calibration process of the main turntable is performed through physical or logical methods. That is, when the preset mechanical origin or sensor triggered reference position is identified, the angle value is set as the system angle reference value, which is used as the angle starting point for all station position mapping and control triggering. The angle reference value is locked in the register through a one-time write action, and is periodically reset according to the cumulative pulse difference in each rotation, ensuring the consistency of the zero point and the offset of the cumulative error in the multi-cycle operation process. Based on the angle reference, combined with the product process requirements and the characteristics of the mechanism arrangement, the key action positions of each actuator are mapped one by one, and the positions such as material taking, material placing, turning and material receiving on the mechanical structure are corresponded to the main turntable angle coordinate system, so as to deduce the main turntable angle coordinates corresponding to the material taking position and the material placing position of the swing arm motor, the turning starting position of the turning motor, the material receiving position of the variable distance motor, and the index reference position of the material receiving disc motor. For example, the material taking position of the swing arm motor is mapped to the 10-degree position of the main turntable, its material placing position is mapped to the 270-degree position, the turning starting position of the turning motor is 85 degrees, the material receiving position of the variable distance motor is 185 degrees, and the index trigger point of the material receiving disc motor is calculated according to the product spacing and the beat requirement, and its angle is adjusted in real time according to the variable distance result. In order to avoid the trigger ambiguity and mechanical response lag problem of each station caused by high-speed rotation, an angle tolerance definition mechanism is introduced for the above angle coordinates, that is, a continuous interval is set around each station action angle coordinate as an effective trigger window, which is defined as the first angle interval. Each first angle interval has different starting angle and ending angle ranges, which are determined by the mechanical structure response time, motor acceleration and deceleration process and action duration. For example, the material taking angle interval of the swing arm motor is set between 10 degrees and 20 degrees, and the material placing angle interval is set between 265 degrees and 275 degrees. The turning action angle interval is dynamically allocated according to the angle number of each station (such as 30 degrees or 45 degrees) and is set in a certain sub-interval within the range of 90 degrees to 275 degrees of the main turntable. The material receiving angle interval of the variable distance motor is set between 180 degrees and 190 degrees. The above intervals are triggered and controlled by real-time angle comparison, and interlocking logic is set in the system to ensure that the next station action cannot be triggered in advance when a certain action is not completed, avoiding motion conflict and structure interference.

[0076] In a specific embodiment, the process of performing step 102 can specifically include the following steps:

[0077] The main tray and the auxiliary tray are detected by the optical fiber sensor to obtain a tape supply state parameter;

[0078] According to the angle reference value, the tape feeding motor is adjusted in the first angle range of the main turntable, and a target position deviation value is calculated;

[0079] Based on the target position deviation value, the carrier tape is compensated left and right, and an actual position coordinate of the carrier tape is obtained;

[0080] Based on the tape supply state parameter and the actual position coordinate of the carrier tape, tape position data is generated;

[0081] Based on the first angle interval, the angle trigger control is performed on the swing arm motor, the turnover motor, the variable distance motor and the material receiving disc motor, and a work station action completion signal is obtained.

[0082] In the embodiment, the main tray and the auxiliary tray are respectively configured with high-sensitivity fiber sensor modules for non-contact monitoring of the remaining length of the material belt. After the sensor signals are collected through the digital input terminal, they are converted into feeding signals for logical judgment. The judgment is made by setting a material belt length threshold value. When the main tray detects that the remaining material belt is lower than the set threshold value, the current feeding channel state is automatically recorded, and the auxiliary tray is triggered to enter a pre-start waiting state, forming a material belt feeding state parameter containing the current feeding source identifier, the remaining amount level, and the switching preparation state. Using the main turntable angle reference coordinate system, when the main turntable runs to a specific first angle range, for example, between 10 degrees and 100 degrees, the feeding motor starts the belt pulling action through real-time angle matching. The feeding motor running speed is not fixed, but is adaptively adjusted according to the current product rhythm, the material belt tension state, and the offset feedback, so that the feeding position is accurately aligned with the filling position in the corresponding period. During the feeding process, the encoder feedback and position comparison logic are used to calculate the deviation between the current pulse value of the feeding motor and the preset target position in real time, and generate a target position deviation value. Based on the target position deviation value, a bidirectional compensation control module is called, and left or right offset compensation actions are performed according to the deviation direction, and the control signal drives the offset execution unit to make a small displacement correction to the carrier tape through pulse modulation, so that the carrier tape position is re-aligned with the system coordinate reference line. The actual position coordinates of the carrier tape in the current period are calculated, and the actual position coordinates of the carrier tape are combined with the feeding state parameter to form the material belt position data. During the running of the main turntable, the first angle range is used as the control trigger window, and the motor control strategies of each key station are connected to the specific angle trigger event. By reading the main turntable angle and the preset trigger interval in real time, when the main turntable enters the first angle range corresponding to a certain station, a start instruction is sent to the motor bound to the current station. For example, when the main turntable turns to 10 degrees to 20 degrees, the swing arm motor is triggered to turn from the waiting position to the material taking position and adsorb the material, and when it is between 270 degrees and 280 degrees, the material is discharged. Similarly, when the main turntable runs to about 85 degrees, the turning motor is triggered to perform a turning action, and when it is about 185 degrees, it enters the distance changing motor receiving area, thereby forming an angle-driven station action chain. After each motor action is completed, the corresponding station action completion signal is generated according to the feedback signal, such as the limit switch contact, the servo in-position signal, or the time counting completion flag, and the station action completion signal is written into the logic register group to form the station state feedback data.

[0083] In a specific embodiment, the process of generating material belt position data based on the material belt feeding state parameter and the actual position coordinates of the carrier tape can specifically include the following steps:

[0084] According to the material belt feeding state parameter, the detection signal of the fiber sensor is time accumulated to obtain the material belt shortage duration and the material belt jam duration;

[0085] The actual position coordinates of the carrier tape are subtracted from the theoretical feeding position to obtain an actual feeding length deviation value, and a compensation trigger signal is generated when the actual feeding length deviation value exceeds a deviation threshold value;

[0086] An abnormality judgment is performed according to the material tape shortage duration and the shortage alarm threshold value and the material tape jamming duration and the jamming alarm threshold value to obtain a material tape feeding abnormality identifier;

[0087] The feeding motor compensation value and the AC motor speed are adjusted according to the compensation trigger signal and the material tape feeding abnormality identifier to obtain material tape position data.

[0088] In the feeding control link in this embodiment, the high-low level change signals output from the optical fiber sensors installed near the positions of the main material tray and the auxiliary material tray are continuously monitored, and the high-low level change signals reflect whether the material belt is in a normal feeding state. When the optical fiber sensor detects that the signal continuously remains in a low level state, it indicates that there is no effective material belt passing through the sensing area, and this state is matched with the material belt shortage event, and an internal time accumulation counter is started to accumulate the duration of this state; when the low level state lasts for more than a set shortage alarm threshold (such as 3000 milliseconds), it is determined that there is a material belt shortage anomaly. If the sensor signal remains in a high level state, but no effective displacement occurs in subsequent feeding, the material belt jamming phenomenon is judged according to this phenomenon and combined with the position offset monitoring, and the high level maintenance time in the material belt jamming state is accumulated, and when the accumulated time exceeds the jamming alarm threshold (such as 1500 milliseconds), it is determined that there is a jamming anomaly. The above two time accumulation processes are constructed by the internal timer and the edge trigger logic of the PLC, which are used to realize the state monitoring and automatic anomaly recognition without interruption. The actual position coordinates reached by the carrier tape after each feeding action of the feeding motor are collected, and real-time difference operation is performed on the actual position coordinates and the theoretical feeding target position to obtain the actual feeding length deviation value of this period. The actual feeding length deviation value is compared with the set maximum allowable deviation threshold (such as ±2mm), and if it exceeds the threshold range, a compensation trigger signal is generated to trigger the compensation calculation module to perform a round of feeding adjustment operation. The compensation mechanism selects the correction path of the feeding motor according to the deviation direction, and dynamically adjusts the pulse number of the feeding motor according to the compensation trigger signal, so that the carrier tape is re-aligned to the reference beat, and at the same time, the running speed of the auxiliary alternating current motor is controlled for fine adjustment to relieve the system inertia deviation caused by uneven tension or friction resistance. The material belt shortage duration and the material belt jamming duration accumulated by the optical fiber sensor are compared and analyzed with the respective alarm thresholds to determine whether a shortage anomaly or a jamming anomaly is formed, and a material belt feeding anomaly identifier with an identification function is generated. The material belt feeding anomaly identifier and the compensation trigger signal are used as input variables of the control system and jointly act on the feeding control module. The control program of the feeding motor determines whether to enter the slow running, intermittent running or stop waiting state according to the anomaly identifier, and adjusts the amplitude and frequency of the feeding pulse output according to the dynamic change of the deviation amount. In order to prevent misjudgment and mechanical fatigue, an anomaly buffer window is set, and when the anomaly enters the threshold critical interval but does not last stably, the forced compensation is not performed and the state change is continued to be observed. The total amount of the feeding motor pulses after compensation and the speed parameter of the alternating current motor are fused and processed, and the material belt position data is finally calculated by combining the sensor feedback state and the carrier tape position deviation correction value.

[0089] In a specific embodiment, the process of obtaining the work position action completion signal based on the angle interval trigger control of the swing arm motor, the turnover motor, the variable distance motor and the material receiving tray motor can specifically include the following steps:

[0090] The current angle value of the main turntable is compared with the first angle interval in real time to obtain a swing arm picking trigger signal, a turnover starting trigger signal, a variable distance receiving trigger signal, and a receiving disc indexing trigger signal;

[0091] According to the swing arm picking trigger signal, when the main turntable reaches the first angle, the swing arm motor is controlled to move from the pre-picking waiting position to the picking position and activate the suction nozzle vacuum electromagnetic valve; when the main turntable reaches the second angle, the swing arm motor is controlled to move to the discharging position and perform the vacuum breaking action, to obtain a swing arm action execution state;

[0092] Based on the turnover starting trigger signal, when the main turntable is in the second angle range, the turnover motor is controlled to perform the station rotation, to obtain a turnover action execution state; at the same time, according to the variable distance receiving trigger signal, when the main turntable reaches the third angle, the variable distance motor is controlled to move to the receiving position, and when the main turntable reaches the fourth angle, the variable distance motor is controlled to move to the discharging position, to obtain a variable distance action execution state;

[0093] The swing arm action execution state, the turnover action execution state, the variable distance action execution state, and the indexing completion state of the receiving disc motor are logically combined to obtain a station action completion signal.

[0094] In this embodiment, the current angle value of the main turntable is compared with the preset first angle interval to determine whether the key action of each station is bound to a specific angle interval. When the main turntable enters a specific angle range, the corresponding control signal generation logic is triggered. When the main turntable reaches a set arm swinging and material taking angle interval (e.g. 10° to 20°), the system sends an arm swinging and material taking trigger signal to drive the swinging arm motor to quickly move from the material taking waiting position to the material taking position, and activates the vacuum electromagnetic valve on the suction nozzle to ensure that the material is firmly adsorbed. As the main turntable continues to rotate and reaches another set material releasing angle interval (e.g. 270° to 280°), the swinging arm motor is controlled again to move from the material taking position to the material releasing position according to the angle position, and performs a vacuum breaking action at the material releasing position to ensure that the material is accurately released to the downstream position. The completion of the swinging arm action is confirmed by the servo position signal or the limit signal, which constitutes the swinging arm action execution state. When the main turntable enters the second angle interval (e.g. 85° to 275°) bound to the flipping motor, it is determined that the flipping start trigger signal has met the conditions, and the flipping motor is immediately instructed to perform an angle accurate control of the station rotation, which completes the spatial direction adjustment of the material. The rotation step is determined by the product specification (e.g. 30° or 45° each time), and the motor action execution state is confirmed by the angle code feedback or the position signal, which constitutes the flipping action execution state. In this process, the main turntable continues to rotate and enters the control interval of the variable distance motor, and when it reaches the third angle interval (e.g. 185°), the system sends a variable distance material receiving trigger signal to control the variable distance motor to move from the waiting position to the material receiving position, and waits to receive the product released by the swinging arm; when the main turntable further rotates to the fourth angle interval (e.g. 285°), the variable distance motor completes the linear movement from the material receiving position to the material releasing position according to the set trajectory, and the displacement process ensures the accurate arrangement of the product in the downstream station. The execution state is also confirmed by the servo feedback or mechanical limit, which constitutes the variable distance action execution state. At the same time, the material receiving disc motor performs the indexing action according to the angle index trigger signal bound thereto when the angle of the main turntable matches, i.e. the material receiving disc advances one station each time a complete product is released, thereby maintaining the structural synchronization with the main turntable and the variable distance motor. The completion of the material receiving disc indexing is confirmed by pulse accumulation and position confirmation, which constitutes the indexing completion state. After the above four types of actuators complete the actions, the swinging arm action execution state, the flipping action execution state, the variable distance action execution state and the indexing completion state of the material receiving disc motor are collected, and the four state signals are combined according to the logic, or logic, interlocking logic, etc. When all four are in the "completed" state, a unified station action completion signal is generated.

[0095] In a specific embodiment, the process of step 103 can specifically include the following steps:

[0096] According to the station action completion signal, the main turntable reaches the fifth angle, triggering the turntable CCD to collect product position and posture images, triggering the sealing tape CCD to collect packaging quality images after the sealing tape action is completed, and triggering the pre-cutting CCD to collect the presence or absence of material discrimination images at the cutting position;

[0097] Feature extraction and template matching are performed on the product position and posture images, the packaging quality images, and the presence or absence of material discrimination images to obtain product position offset and angle deviation values of the turntable station, sealing integrity parameters of the sealing tape station, and presence or absence of material determination results of the pre-cutting station;

[0098] Based on the product position offset, the angle deviation value, the sealing integrity parameter, and the presence or absence of material determination result, product quality data is generated.

[0099] In this embodiment, the PLC or the upper controller monitors the action completion signals of each key station in real time. When all the preset station state completion signals are received and it is determined that the main turntable rotation angle reaches the fifth angle (for example, 450 degrees) in a specific visual acquisition interval, the turntable CCD installed at the 450-degree position is triggered to start the image acquisition process. The main turntable angle is latched and the image acquisition module is started, and the image information of the current station product is acquired by a high-speed camera. The image contains the product edge, alignment mark and actual attitude angle. At the moment when the sealing belt mechanism completes the heat sealing action and outputs the sealing belt completion signal, the sealing belt CCD located above the heat sealing area is triggered to acquire the image of the heat sealing area, which is used to evaluate the integrity, uniformity and welding deformation of the seal. When the product runs to the set position 20 mm before the cutting station, the control system determines and triggers the pre-cutting CCD to take a picture for material detection according to the main turntable angle, and the image is used to determine whether there is a problem of product omission, misplacement or empty running, thereby assisting the judgment of whether the cutting action is executed. The product contour extraction and edge recognition operation is performed on the image acquired by the turntable CCD, the gradient direction filtering algorithm is used to extract the boundary line and center point coordinates of the product in the image, the template matching operation is performed combined with the built-in template image, the translation amount and rotation angle between the actual image and the standard template are calculated, and the product position offset and attitude angle deviation values are obtained. The offset is expressed in millimeters to indicate whether the product deviates from the standard filling track, and the angle deviation value is expressed in degrees to reflect whether the product has an error in the rotation direction. The region gray scale analysis and edge contrast analysis are performed on the sealing belt CCD image to extract the integrity features of the heat sealing area, such as the closed continuity of the seal boundary, the bubble residue in the middle of the sealing belt, the virtual welding phenomenon or the fusion crack situation, the uniformity of the image gray texture change is used to judge the pressing quality, and the seal integrity parameters are extracted. At the same time, the pre-cutting CCD image is input into the material recognition module, the binary processing and background template comparison are used to identify whether there is an effective material image feature on the carrier tape track, the brightness distribution and edge structure of the target block are used to judge whether it is an actual product, and the presence or absence of material determination result is made. After integrating the image analysis results output by the above three CCD detection channels, a set of multi-dimensional product quality data structure including “position offset, angle deviation value, seal integrity parameter, presence or absence of material determination result” is constructed.

[0100] In a specific embodiment, the process of performing feature extraction and template matching on the product position and attitude image, the packaging quality image and the presence or absence of material discrimination image to obtain the product position offset and angle deviation value of the turntable station, the seal integrity parameter of the sealing belt station and the presence or absence of material determination result of the pre-cutting station can specifically include the following steps:

[0101] The product position and posture image is subjected to edge detection and centroid positioning calculation to obtain product contour features, the sealing quality image is subjected to sealing area segmentation and connected domain analysis to obtain sealing area features, and the presence or absence of material discrimination image is subjected to binarization and contour extraction to obtain target contour features;

[0102] The product contour features are matched with a preset product standard template to obtain a position offset pixel value and an angle rotation value, the sealing area features are subjected to similarity calculation with a sealing standard template to obtain a sealing continuity value, and the target contour features are subjected to area comparison with a material piece template to obtain a material presence determination value;

[0103] The product position offset amount is calculated based on the position offset pixel value and a pixel calibration coefficient, the angle deviation value is calculated based on the angle rotation value and an angle correction coefficient, the sealing integrity parameter is calculated based on the sealing continuity value and an integrity threshold value, and the presence or absence of material determination result is obtained based on the comparison between the material presence determination value and a determination threshold value.

[0104] In this embodiment, the main turntable CCD image is used to reflect the actual position and posture of the product on the turntable station, the sealing tape CCD image is used to capture the sealing boundary state, and the pre-cutting CCD image is used to judge whether there is a material in the carrier tape path. For the main turntable CCD image, the edge of the target area in the image is identified by an edge detection algorithm, and a Canny edge detector is used to eliminate noise and extract high-contrast boundary lines in cooperation with median filtering. The area centroid coordinates and the main direction angle are calculated in the extracted edge profile by a centroid positioning calculation method, and the product profile features including the outer contour point set, the centroid coordinates and the direction vector are formed. The product profile features are matched with the preset standard product profile template as the matching basis, and the offset position and the rotation angle of the product in the current image frame are calculated by affine transformation and least squares fitting, so as to obtain the position offset pixel value and the angle rotation value. For the sealing quality image, the sealing area is segmented and extracted by gray projection or region growing algorithm, and the sealing heat sealing area is separated from the background, and then the connected domain analysis method is used to detect whether there are breakpoints, holes, excessive overlap or virtual welding phenomena on the sealing path. In the analysis process, multiple characteristic parameters such as the connectivity of the sealing boundary, the edge integrity rate, the area ratio and the gray consistency are calculated, and the multiple characteristics are compared with the ideal sealing profile recorded in the sealing standard template. The sealing continuity value of the current image and the standard image is calculated by using the profile matching similarity index, which is used to quantify whether the sealing is continuous, stable and complete. At the same time, when the pre-cutting CCD image is preprocessed, the image is first subjected to adaptive threshold processing to obtain a binary result, so as to enhance the contrast between the material and the background. Then the material boundary in the image is identified by a contour extraction algorithm such as the FindContours function, and the target contour features are calculated based on the contour area. The target contour features are compared with the standard material template area in proportion, and the material existence judgment value is obtained, which is used to quantitatively judge whether there is material entering the cutting area in the current frame. The position offset pixel value is multiplied by the pixel calibration coefficient to convert it into the product position offset in millimeters, which is used to represent the actual deviation distance of the product relative to the ideal filling center. The angle rotation value is multiplied by the angle correction coefficient to convert it into the angle deviation value, which is used to judge whether there is a problem of incorrect posture of the product on the turntable. The sealing continuity value is compared with the integrity threshold value, and if the value is lower than the threshold value, it is considered that the sealing has cracks, insufficient fusion or other heat sealing abnormalities, and the sealing integrity parameter is calculated, which is set as a qualified or unqualified identification value. The material existence judgment value is compared with the preset judgment threshold value, and when the contour area ratio is lower than the threshold value or the target contour does not exist, it is determined that there is no material, and the material existence judgment result is output. The above four detection results are combined to form the product quality data structure.

[0105] In a specific embodiment, the process of step 104 can specifically include the following steps:

[0106] According to the bad product position mark and yield distribution in the product quality data, a cutting parameter adjustment is performed to obtain a cutting speed target value, and according to the actual position coordinates of the material belt position data, a cutting position compensation is performed to obtain a cutting position compensation value;

[0107] Based on the cutting speed target value and the cutting position compensation value, the cutting motor is controlled to move to a pre-pressing position of the cutting position to apply a pre-pressing force, then a cutting action is completed and a cutting back-blowing is triggered to obtain a cutting completion state signal and a cutting position record;

[0108] According to the cutting completion state signal, a sealing belt mechanism is triggered, and according to the set number of front empty, filling and rear empty, a sealing belt length is controlled to obtain a packaging completion state signal and a packaging parameter record;

[0109] According to the packaging completion state signal, the cutting position record, the packaging parameter record, the whole machine yield in the product quality data and the double-turntable discharging frequency are integrated to obtain product processing completion data;

[0110] Based on the product processing completion data, a second angle interval triggered by each station action is calculated.

[0111] In this embodiment, a real-time analysis mechanism for product quality data is established to identify the position of defective products in the cutting sequence and dynamically adjust the cutting strategy in combination with continuous yield statistics. When a defective product position marker is identified in the product quality data, the feeding beat corresponding to the defective product is detected, and the position where the defective product is located is used as a constraint condition to adjust the cutting motion characteristics; if defective products are concentrated or appear continuously in a certain section with an increased frequency, the current yield distribution is evaluated by a moving average method, and the cutting speed is appropriately reduced under the premise of ensuring stable production capacity to obtain a cutting speed target value. At the same time, by reading the actual position coordinates of the carrier tape contained in the tape position data and comparing them with the theoretical cutting reference position in real time, the cutting position error value of the current cycle is calculated, and the cutting position error is evaluated to form a cutting position compensation value. In the cutting preparation stage, the control system jointly controls the motion trajectory of the cutting motor according to the cutting speed target value and the cutting position compensation value, drives the motor to the preset pre-press position, i.e., 2 mm above the cutting point, and applies a stable pressing force with a set pressure parameter (such as 30-50 N) to ensure that the tape is fully pressed before cutting to avoid sliding; the cutting motor performs the main cutting action at the dynamically adjusted speed, completes the pressing process from the pre-press position to the target depth within 20 ms, and synchronously triggers the blowback action at the moment of cutting completion, which uses high-pressure gas to quickly remove the cutting residue to prevent residue from affecting the next cycle, generates a cutting completion status signal after completion, and records the cutting position and compensation offset value to form a cutting position record. According to the cutting completion status signal, the sealing belt mechanism is triggered, the current sealing belt length is dynamically calculated according to the set front empty quantity, filling quantity, and rear empty quantity parameters, the sealing belt displacement and the start time of the heat sealing process are controlled according to the current sealing belt length, and the heat sealing temperature and duration parameters are set according to different materials. After the sealing process is completed, a sealing completion status signal is generated, and the actual sealing parameters such as temperature, time, pressure, and sealing belt movement distance during the sealing process are recorded to form a sealing parameter record data structure. The cutting position record and sealing parameter record generated in this cycle are integrated with the machine yield statistics in the current product quality data and the current outfeed times of the double turntables to generate standardized product processing completion data. Based on the product processing completion data, the time consumed by each station action in the full cycle of the main turntable is back calculated, and the original first angle interval is modified in combination with the statistical distribution of cutting and sealing time and quality feedback to generate a second angle interval.

[0112] In a specific embodiment, the process of calculating the second angle interval of the station action trigger based on the product processing completion data can specifically include the following steps:

[0113] The good product quantity, the waste product quantity and the processing time stamp in the product processing completion data are subjected to deviation statistics to obtain production performance deviation parameters and defective product distribution data of each station;

[0114] Fault analysis is performed on the swing arm material taking, the turnover action, the variable distance material receiving and the cutting and packaging according to the defective product distribution data of each station to obtain a target priority sequence;

[0115] Angle compensation is performed based on the production performance deviation parameters and the target priority sequence to obtain an angle adjustment amount of each station;

[0116] The angle adjustment amount of each station is superimposed with the first angle interval to generate a second angle interval triggered by the action of each station.

[0117] In this embodiment, the product processing completion data is periodically summarized and deviation analyzed. The product processing completion data includes the number of good products, the number of defective products and the corresponding processing time stamp under each production beat. The data in a specified time period is sorted and counted by setting a time window. The good product rate, defective product rate and abnormal fluctuation frequency per unit time are calculated. The results are compared with the ideal capacity benchmark to form the production performance deviation parameter representing the overall running state. At the same time, the location of the defective product is traced. The production time stamp corresponding to each defective product is reversely matched with the action information of the workstations in the processing path to locate the specific workstation operations such as arm picking, turning action, distance changing, material receiving and cutting and packaging. The defective product distribution data of each workstation is constructed based on the statistical frequency. The frequency, type difference and duration of the defective product triggering in different workstations are compared horizontally to deduce the fault correlation and possible control deviation of each workstation. The fault analysis is performed based on the defective product distribution data of each workstation. The weighted distribution matrix algorithm is introduced to quantify the defective frequency and fault type influence factor of each workstation. The influence is evaluated in combination with the mechanical structure complexity, error transmission path and action duration of each workstation to comprehensively evaluate the contribution degree of each workstation to the overall defective rate. The evaluation results are sorted to obtain a target priority sequence. The workstation arrangement order that needs to be executed angle compensation or precision adjustment most in the current period is pointed out. For example, if the defective product number and the NG proportion related to the deviation of the arm picking workstation are significantly higher than those of the turning or cutting workstation, the priority of the arm picking workstation in the sequence is automatically promoted as the preferred target of angle compensation calculation. The production performance deviation parameter and the target priority sequence are jointly input into the angle compensation module. The module calculates the required angle adjustment amount based on the current deviation characteristics, cycle average response delay and load fluctuation trend of each priority workstation. The angle adjustment amount is represented by a floating point correction value. The optimal angle correction value is dynamically generated based on the speed of the main turntable and the reaction time delay of the corresponding workstation to make the action triggering time of the corresponding workstation in the next cycle advance or delay to match the response difference in the actual mechanical movement process. The angle adjustment amount of each workstation is added to the original defined first angle interval one by one. The start angle and end angle of the angle interval of each workstation are added to the corresponding adjustment value to form the second angle interval after correction.

[0118] The intelligent control method of the cutting double-turntable ribbon weaving machine in the embodiment of the application is described above. The intelligent control system of the cutting double-turntable ribbon weaving machine in the embodiment of the application is described below. Please refer to Figure 2 The intelligent control system of the cutting double-turntable ribbon weaving machine in the embodiment of the application includes one embodiment:

[0119] The rotation angle acquisition and calibration module 201 is used for acquiring and calibrating the rotation angle of the angle encoder of the main turntable to obtain an angle reference value and a first angle interval of the action triggering of each workstation.

[0120] The angle trigger control module 202 is configured to monitor the material belt position data according to the angle reference value, and perform angle trigger control based on the first angle interval to obtain a work station action completion signal;

[0121] The product visual inspection module 203 is configured to perform product visual inspection based on the work station action completion signal to obtain product quality data;

[0122] The cutting and sealing belt linkage control module 204 is configured to perform cutting and sealing belt linkage control based on the product quality data and the material belt position data to obtain product processing completion data and calculate a second angle interval for triggering each work station action.

[0123] Through the cooperation of the above-mentioned components, through real-time acquisition and calibration of the main turntable angle encoder, a unified angle reference value is established, each work station action is triggered based on an accurate angle interval, the cumulative error of traditional time sequence control is eliminated, and the accurate synchronization of multi-station actions is ensured. According to the angle reference value, the tension control and displacement compensation of the double-material belt feeding motor are performed, the material belt state is monitored in real time through the optical fiber sensor, the feeding speed and position are automatically adjusted, and the occurrence of faults such as belt breakage and material jamming is effectively prevented. Based on the first angle interval, the angle trigger control of the swing arm motor, the turnover motor, the variable distance motor and the material receiving disc motor is unified, the actions of each motor are coordinated with each other, a complete work station action completion signal is formed, and the continuity and stability of product transmission are ensured. Through the three-level visual inspection system of the turntable CCD, the sealing belt CCD and the cutting front CCD, the product position, posture, packaging quality and material state are comprehensively detected, defective products are timely discovered and removed, and the product quality is ensured. Based on the product quality data and the material belt position data, the cutting parameters and the sealing control strategy are dynamically adjusted, the accurate compensation of the cutting position and the flexible control of the sealing length are realized, and the processing precision and the packaging quality are improved. By analyzing the product processing completion data, the second angle interval is automatically calculated, the control parameters are dynamically adjusted according to the production performance deviation and the distribution of defective products of each work station, and the self-learning and self-optimization of the control system are realized. Key data such as cutting position, packaging parameters and overall machine yield rate are recorded to form complete product processing completion data, which is convenient for tracing and quality analysis of the production process. Through the angle mapping and interval adjustment mechanism, different product specifications can be quickly adapted to production requirements, the changeover debugging time is reduced, and the versatility and flexibility of the equipment are improved.

[0124] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working processes of the above-mentioned system, system and unit can refer to the corresponding processes in the foregoing method embodiments, which will not be described herein.

[0125] The integrated unit, if implemented in the form of a software function unit and sold or used as an independent product, can be stored in a computer readable storage medium. Based on such understanding, the technical solutions of the present application or the entire or part of the technical solutions that essentially contribute to the prior art can be embodied in the form of a software product. The computer software product is stored in a storage medium and includes a plurality of instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the method described in the various embodiments of the present application. The aforementioned storage medium includes: a U disk, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk, and various media that can store program codes.

[0126] The above description and the above embodiments are only used to illustrate the technical solutions of the present application, but not to limit them. Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that they can modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacements for some technical features. These modifications or replacements do not make the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A method for intelligent control of cutting a double carousel braider, characterized in that, The application relates to a product processing system and a product processing method. The angle encoder of the main rotating disc is used for rotating angle acquisition and calibration, so that an angle reference value and a first angle interval of each work station action triggering are obtained; The angle reference value is used for monitoring material belt position data, and angle triggering control is carried out based on the first angle interval, so that a work station action completion signal is obtained; specifically, the optical fiber sensor is used for detecting the material belt surplus of the main material disc and the auxiliary material disc, so that a material belt supply state parameter is obtained; the angle reference value is used for adjusting the material feeding motor when the main rotating disc is in a first angle range, so that a target position deviation value is calculated; the target position deviation value is used for carrying out left and right offset compensation of the material belt, so that actual position coordinates of the material belt are obtained; The material belt supply state parameter and the actual position coordinates of the material belt are used for generating material belt position data; the first angle interval is used for carrying out angle triggering control on the swing arm motor, the turnover motor, the variable distance motor and the material receiving disc motor, so that a work station action completion signal is obtained; The work station action completion signal is used for product visual detection, so that product quality data is obtained; The product quality data and the material belt position data are used for carrying out cutting and sealing belt linkage control, so that product processing completion data is obtained and a second angle interval of each work station action triggering is calculated.

2. The intelligent control method of cutting double carousel ribbon machine according to claim 1, characterized in that, The angle encoder of the main rotating disc is used for rotating angle acquisition and calibration, so that an angle reference value and a first angle interval of each work station action triggering are obtained; The angle encoder of the main rotating disc is used for rotating angle acquisition and calibration, so that an angle reference value and a first angle interval of each work station action triggering are obtained; The angle reference value is used for angle mapping of the material taking position and the material placing position of the swing arm motor, the turnover starting position of the turnover motor, the material receiving position of the variable distance motor and the index position of the material receiving disc motor, so that angle coordinates of each motor work station are obtained; The angle coordinates of each motor work station are used for determining a first angle interval of each work station action triggering, and the first angle interval comprises a swing arm material taking angle interval, a swing arm material placing angle interval, a turnover action angle interval and a variable distance material receiving angle interval. The material belt supply state parameter is used for time accumulation of the detection signal of the optical fiber sensor, so that a material belt shortage duration and a material belt jamming duration are obtained; 3. The intelligent control method of cutting double carousel ribbon machine as claimed in claim 1 wherein, The actual material feeding length deviation value is obtained by difference calculation of the actual position coordinates of the material belt and the theoretical material feeding position; when the actual material feeding length deviation value exceeds a deviation threshold value, a compensation triggering signal is generated; The material belt shortage duration and the material belt jamming duration are used for abnormality judgment with a material shortage alarm threshold value and a material jamming alarm threshold value, so that a material belt supply abnormality identifier is obtained; The compensation triggering signal and the material belt supply abnormality identifier are used for adjusting the material feeding motor compensation value and the alternating current motor rotating speed, so that material belt position data is obtained. The first angle interval is used for angle triggering control on the swing arm motor, the turnover motor, the variable distance motor and the material receiving disc motor, so that a work station action completion signal is obtained; ​ 4. The intelligent control method of cutting double carousel ribbon machine according to claim 3, characterized in that, ​ Real-time comparison is made between the current angle value of the main rotating disc and the first angle interval to obtain a swing arm material taking trigger signal, a turnover starting trigger signal, a variable distance material receiving trigger signal and a material receiving disc indexing trigger signal; According to the swing arm material taking trigger signal, when the main rotating disc reaches the first angle, the swing arm motor is controlled to move from a material taking standby position to a material taking position and the suction nozzle vacuum electromagnetic valve is activated, and when the main rotating disc reaches the second angle, the swing arm motor is controlled to move to a material placing position and perform a vacuum breaking action, to obtain a swing arm action execution state; According to the variable distance material receiving trigger signal, when the main rotating disc reaches the third angle, the variable distance motor is controlled to move to a material receiving position, and when the main rotating disc reaches the fourth angle, the variable distance motor is controlled to move to a material placing position, to obtain a variable distance action execution state; The swing arm action execution state, the turnover action execution state, the variable distance action execution state and an indexing completion state of the material receiving disc motor are logically combined to obtain a work station action completion signal.

5. The intelligent control method of cutting double carousel ribbon machine as claimed in claim 1, wherein, The product visual inspection is performed based on the work station action completion signal to obtain product quality data, including: According to the work station action completion signal, when the main rotating disc reaches the fifth angle, a rotating disc CCD is triggered to collect a product position and posture image, when a sealing band action is completed, a sealing band CCD is triggered to collect a sealing quality image, and when a cutting position is reached, a pre-cutting CCD is triggered to collect a material presence / absence discrimination image; Feature extraction and template matching are performed on the product position and posture image, the sealing quality image and the material presence / absence discrimination image to obtain a product position offset and an angle deviation value of the rotating disc work station, a sealing integrity parameter of the sealing band work station and a material presence / absence determination result of the pre-cutting work station; The product quality data is generated based on the product position offset, the angle deviation value, the sealing integrity parameter and the material presence / absence determination result.

6. The intelligent control method of cutting double carousel ribbon machine according to claim 5, characterized in that, The feature extraction and template matching on the product position and posture image, the sealing quality image and the material presence / absence discrimination image to obtain the product position offset and the angle deviation value of the rotating disc work station, the sealing integrity parameter of the sealing band work station and the material presence / absence determination result of the pre-cutting work station, including: Edge detection and centroid positioning calculation are performed on the product position and posture image to obtain product contour features, sealing region segmentation and connected domain analysis are performed on the sealing quality image to obtain sealing region features, and binarization and contour extraction are performed on the material presence / absence discrimination image to obtain target contour features; The product contour features are matched with a preset product standard template to obtain a position offset pixel value and an angle rotation value, the sealing region features are similarity calculated with a sealing standard template to obtain a sealing continuity value, and the target contour features are area compared with a material piece template to obtain a material piece presence determination value; The product position offset is calculated based on the position offset pixel value and a pixel calibration coefficient, the angle deviation value is calculated based on the angle rotation value and an angle correction coefficient, the sealing integrity parameter is calculated based on the sealing continuity value and an integrity threshold, and the presence of material determination result is obtained based on the comparison between the material presence determination value and a determination threshold.

7. The intelligent control method of cutting double carousel ribbon machine as claimed in claim 1, wherein, The cutting and sealing belt linkage control is performed based on the product quality data and the material belt position data to obtain product processing completion data and calculate a second angle interval of each work station action trigger, including: The cutting parameter is adjusted according to the defective product position mark and yield distribution in the product quality data to obtain a cutting speed target value, and the cutting position compensation value is obtained by performing cutting position compensation according to the actual position coordinates of the material belt in the material belt position data; The cutting motor is controlled to move to a pre-pressing position of the cutting position to apply a pre-pressing force based on the cutting speed target value and the cutting position compensation value, then the cutting action is completed and cutting back-blowing is triggered to obtain a cutting completion state signal and a cutting position record; The sealing belt mechanism is triggered according to the cutting completion state signal, and the sealing belt length is controlled according to the set number of front empty, filling and rear empty to obtain a sealing completion state signal and a sealing parameter record; The cutting position record, the sealing parameter record, the overall yield in the product quality data and the double-turntable discharging frequency are integrated according to the sealing completion state signal to obtain product processing completion data; The second angle interval of each work station action trigger is calculated based on the product processing completion data.

8. The intelligent control method of cutting double carousel ribbon machine according to claim 7, characterized in that, The second angle interval of each work station action trigger is calculated based on the product processing completion data, including: The deviation statistics of the good product quantity, the defective product quantity and the processing time stamp in the product processing completion data are performed to obtain production performance deviation parameters and defective product distribution data of each work station; Fault analysis is performed on the swing arm material taking, the turnover action, the variable-distance material receiving and the cutting and sealing according to the defective product distribution data of each work station to obtain a target priority sequence; Angle compensation is performed based on the production performance deviation parameters and the target priority sequence to obtain angle adjustment amounts of each work station; The angle adjustment amounts of each work station are superimposed on the first angle interval to generate the second angle interval of each work station action trigger.

9. An intelligent control system for cutting a double carousel braider, characterized in that, The intelligent control method for cutting a double-turntable braiding machine as claimed in any one of claims 1-8, including: A rotation angle acquisition and calibration module is configured to acquire and calibrate the rotation angle of an angle encoder of a main turntable to obtain an angle reference value and a first angle interval of each work station action trigger; An angle trigger control module is configured to monitor material belt position data according to the angle reference value and perform angle trigger control based on the first angle interval to obtain a work station action completion signal; A product visual detection module is configured to perform product visual detection based on the work station action completion signal to obtain product quality data; A cutting and sealing belt linkage control module is configured to perform cutting and sealing belt linkage control based on the product quality data and the material belt position data to obtain product processing completion data and calculate a second angle interval of each work station action trigger.

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