Automatic screening and grading system for high-purity zirconium oxide beads

Abstract

The invention relates to the technical field of high-purity zirconia bead production, in particular to a high-purity zirconia bead automatic screening and grading system which comprises a size detection unit, a grading judgment unit, a dynamic distribution unit, a quality evaluation unit and an intelligent monitoring terminal. The system measures the diameter in real time through a high-precision optical sensor, generates a screening signal, and carries out real-time monitoring and risk assessment on the grading process based on grading strategy control operation in combination with a parameter tracking feedback module and a grading influence assessment module. The screening efficiency and the grading precision can be improved, the product quality consistency is ensured, the high-end market requirement is met, and meanwhile the intelligent level and the operation stability are improved.

Description

Technical Field

[0001] This invention relates to the field of high-purity zirconia bead production technology, and more specifically, to an automatic screening and grading system for high-purity zirconia beads. Background Technology

[0002] With the widespread application of high-purity zirconia beads in precision grinding, ceramic bearings, medical devices, and electronic packaging, their dimensional accuracy, roundness, surface quality, and purity have an increasingly significant impact on product performance. Traditional manual screening methods have limitations in efficiency and accuracy, and the screening results are easily affected by human factors, making it difficult to fully meet the stringent quality requirements of the high-end market. Although some automated equipment is used for screening in existing technologies, there is still room for improvement in grading accuracy, operational stability, and adaptability, and its ability to control quality under complex working conditions is limited. In addition, existing systems lack real-time monitoring and evaluation of key parameters during the screening process, which may affect overall production efficiency and product consistency, and the level of intelligence needs to be further improved. Summary of the Invention

[0003] The purpose of this invention is to provide an automated screening and grading system for high-purity zirconia beads, which solves the problems of low efficiency and large errors in manual screening in existing technologies, while also overcoming the shortcomings of traditional automated equipment in terms of grading accuracy, operational stability, and adaptability. Furthermore, existing technologies lack real-time monitoring and evaluation of key parameters, making it difficult to meet the stringent requirements of high-end markets for product quality consistency, and their level of intelligence is relatively low.

[0004] The above-mentioned technical objective of the present invention is achieved through the following technical solution: an automatic screening and grading system for high-purity zirconia beads, comprising a size detection unit, a grading determination unit, a dynamic allocation unit, a quality assessment unit, and an intelligent monitoring terminal; the size detection unit measures the diameter of the high-purity zirconia beads in real time using a high-precision optical sensor and sends the measurement data to the grading determination unit; the grading determination unit calculates the current size characteristic value of the high-purity zirconia beads based on the measurement data, and generates a first-level screening signal, a second-level screening signal, or a third-level screening signal accordingly, and sends the first-level screening signal, the second-level screening signal, or the third-level screening signal to the dynamic allocation unit and the intelligent monitoring terminal;

[0005] The dynamic allocation unit determines the current grading strategy matched to the high-purity zirconia beads based on the corresponding screening signals. The first-level screening signal, the second-level screening signal, and the third-level screening signal correspond to the high-speed grading strategy, the medium-speed grading strategy, and the low-speed grading strategy, respectively. Based on the matched grading strategy, the unit controls the grading operation for the high-purity zirconia beads and sends the grading information to the intelligent monitoring terminal. The quality assessment unit analyzes the data to determine the quality risk of the grading process and generates a high-risk or low-risk grading signal. The unit then sends the high-risk or low-risk grading signal to the intelligent monitoring terminal. When the intelligent monitoring terminal receives a high-risk grading signal, it issues a corresponding warning.

[0006] Furthermore, the specific analysis process of the hierarchical determination unit is as follows:

[0007] The system acquires the diameter measurement value at the current time node and the diameter measurement value at the adjacent previous time node, and labels them as the first diameter and the second diameter. The change in the second diameter compared to the first diameter is labeled as the third diameter. A grading judgment value is obtained by weighted summation of the first diameter and the third diameter. The grading judgment value is then compared with a preset grading judgment value range. If the grading judgment value exceeds the maximum value of the preset grading judgment value range, a first-level filtering signal is generated. If the grading judgment value is within the preset grading judgment value range, a second-level filtering signal is generated. If the grading judgment value does not exceed the minimum value of the preset grading judgment value range, a third-level filtering signal is generated.

[0008] Furthermore, the quality assessment unit is connected to the parameter tracking and feedback module. The parameter tracking and feedback module tracks and monitors the grading process of high-purity zirconia beads, analyzes the deviation of the grading execution to determine whether the grading is in an unreasonable state, and sends the analysis and judgment information to the quality assessment unit in real time.

[0009] Furthermore, the specific analysis process of the parameter tracking feedback module includes: collecting the vibration frequency during the grading process of high-purity zirconia beads and marking it as the vibration detection value; collecting the conveyor belt speed and grading chamber pressure and marking them as the conveyor speed detection value and the chamber pressure detection value, respectively; comparing the vibration detection value, conveyor speed detection value, and chamber pressure detection value with the preset vibration detection value range, preset conveyor speed detection value range, and preset chamber pressure detection value range, respectively; if the vibration detection value, conveyor speed detection value, or chamber pressure detection value is not within the corresponding preset range, it is determined that the current grading is in an unreasonable state.

[0010] Furthermore, if the vibration detection value, conveying speed detection value, and cavity pressure detection value are all within their respective preset ranges, the vibration detection value is calculated by subtracting the median of the preset vibration detection value range and taking the absolute value to obtain the vibration characteristic value. Similarly, the conveying characteristic value and cavity pressure characteristic value are obtained. The parameter tracking value is obtained by weighted summation of the vibration characteristic value, conveying characteristic value, and cavity pressure characteristic value. The parameter tracking value is compared with the preset parameter tracking threshold. If the parameter tracking value exceeds the preset parameter tracking threshold, it is determined that the current state is in an unreasonable classification state.

[0011] Furthermore, the specific analysis process of the quality assessment unit includes: timing the process from when the current state is determined to be categorized as irrational until the categorized irrational state ends, thereby obtaining the duration of a single instance of categorized irrationality; marking the sum of all categorized irrational single-instance durations within a unit of time as the categorized irrationality detection value; comparing the categorized irrationality detection value with a preset categorized irrationality detection threshold; if the categorized irrationality detection value exceeds the preset categorized irrationality detection threshold, a categorized high-risk signal is generated; if the categorized irrationality detection value does not exceed the preset categorized irrationality detection threshold, the duration of a single instance of categorized irrationality is compared with the preset threshold for the duration of a single instance of categorized irrationality. The system compares numerical values ​​to count the number of instances of unreasonable duration exceeding a preset threshold within a unit of time and marks them as unreasonable risk values. It also marks the instance with the largest unreasonable duration within a unit of time as an unreasonable amplitude value. A quality assessment value is calculated by weighted summation of the unreasonable detection value, the unreasonable risk value, and the unreasonable amplitude value. This quality assessment value is then compared with a preset quality assessment threshold. If the quality assessment value exceeds the threshold, a high-risk signal is generated; otherwise, a low-risk signal is generated.

[0012] Furthermore, the quality assessment unit communicates with the graded impact assessment module. The quality assessment unit sends a graded low-risk signal to the graded impact assessment module. When the graded impact assessment module receives the graded low-risk signal, it analyzes the potential graded hazards of the high-purity zirconia beads and generates a graded impact alarm signal or a graded impact safety signal accordingly. The graded impact alarm signal or graded impact safety signal is then sent to the intelligent monitoring terminal. When the intelligent monitoring terminal receives the graded impact alarm signal, it issues a corresponding warning.

[0013] Furthermore, the specific analysis process of the graded impact assessment module is as follows: The equipment associated with the grading of high-purity zirconia beads is collected, and the corresponding equipment is marked as the affected object i, where i is a natural number greater than 1; the time elapsed between the installation date and the current date of affected object i is collected and marked as the installation duration; the installation duration is compared with the corresponding preset installation duration threshold; if the installation duration exceeds the corresponding preset installation duration threshold, affected object i is marked as an abnormal object; if the installation duration does not exceed the corresponding preset installation duration threshold, the total duration for which affected object i has been in operation throughout the historical period is marked as the working duration; the working duration is compared with the corresponding preset working duration threshold; if the working duration exceeds the corresponding preset working duration threshold, affected object i is marked as an abnormal object; if there are abnormal objects among the equipment associated with the grading of high-purity zirconia beads, a graded impact alarm signal is generated.

[0014] Furthermore, if there are no abnormal objects in the equipment associated with the grading of high-purity zirconia beads, the ratio of the installation time of affected object i to the corresponding preset installation time threshold is marked as the installation time value, and the average of the installation time values ​​of all equipment is marked as the installation time analysis value. Similarly, the ratio of the working time of affected object i to the corresponding preset working time threshold is marked as the working time value, and the average of the working time values ​​of all equipment is marked as the working time analysis value. Furthermore, starting from the current moment and tracing back forward to set a detection cycle, the number of times the grading process cannot proceed normally due to equipment failure within the detection cycle is collected, and this number is compared with the total grading process time within the detection cycle to obtain the operational fault value. The grading impact characteristic value is obtained by weighted summation of the installation time analysis value, the working time analysis value, and the operational fault value. The grading impact characteristic value is then compared with the preset grading impact characteristic threshold. If the grading impact characteristic value exceeds the preset grading impact characteristic threshold, a grading impact alarm signal is generated; if the grading impact characteristic value does not exceed the preset grading impact characteristic threshold, a grading impact safety signal is generated.

[0015] In summary, the present invention has the following advantages: The system includes a size detection unit, a grading determination unit, a dynamic allocation unit, a quality assessment unit, and an intelligent monitoring terminal. It measures the diameter in real time and generates screening signals through a high-precision optical sensor, controls the operation based on the grading strategy, and combines a parameter tracking feedback module and a grading impact assessment module to monitor and assess the risk of the grading process in real time. This can improve screening efficiency and grading accuracy, ensure product quality consistency, meet the needs of the high-end market, and enhance the level of intelligence and operational stability. Attached Figure Description

[0016] Figure 1 This is a structural block diagram of the automatic screening and grading system for high-purity zirconia beads of the present invention.

[0017] Figure 2 This is a detailed flowchart illustrating the grading determination unit and quality assessment unit of the present invention.

[0018] Figure label:

[0019] 1. Size detection unit; 2. Grading judgment unit; 3. Dynamic allocation unit; 4. Quality assessment unit; 5. Intelligent monitoring terminal; 6. Parameter tracking and feedback module; 7. Grading impact assessment module. Detailed Implementation

[0020] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0021] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly or indirectly attached to that other component. When a component is referred to as being "connected to" another component, it can be directly or indirectly connected to that other component.

[0022] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0024] This invention provides an automatic screening and grading system for high-purity zirconia beads, the structural block diagram of which is shown below. Figure 1As shown, the system includes a size detection unit 1, a grading determination unit 2, a dynamic allocation unit 3, a quality assessment unit 4, and an intelligent monitoring terminal 5. These units are interconnected via data transmission lines to form a complete automated screening and grading system. The size detection unit 1, located at the beginning of the system, measures the diameter of the high-purity zirconia beads in real time and transmits the measurement data to the grading determination unit 2. After receiving the data from the size detection unit 1, the grading determination unit 2 generates a screening signal according to a preset algorithm and sends it to the dynamic allocation unit 3 and the intelligent monitoring terminal 5. The dynamic allocation unit 3 performs the grading operation based on the received screening signal and feeds back the grading result to the intelligent monitoring terminal 5. The quality assessment unit 4 is communicatively connected to the parameter tracking feedback module 6, used to analyze the quality risks of the grading process and generate a grading risk signal to be sent to the intelligent monitoring terminal 5. The grading impact assessment module 7 is communicatively connected to the quality assessment unit 4, used to further analyze potential hazards during the grading process and generate alarm or safety signals.

[0025] In specific implementation, the size detection unit 1 uses a high-precision optical sensor as its core component. This sensor is installed above the conveyor belt to ensure non-contact measurement of the diameter of the high-purity zirconia beads. The high-precision optical sensor acquires the contour information of the high-purity zirconia beads through photoelectric signals and converts it into a diameter measurement value. After receiving the diameter measurement value from the size detection unit 1, the grading and determination unit 2 first obtains the first diameter at the current time point and the second diameter at the adjacent previous time point. By calculating the change in the second diameter relative to the first diameter, the third diameter is obtained. The grading and determination unit 2 performs a weighted summation operation on the first diameter and the third diameter to obtain a grading and determination value. The weighting coefficients of the weighted summation can be obtained by batch testing standard size samples to obtain empirical data and fitting using the least squares method. For example, in a specific embodiment, the weighting coefficient of the first diameter can be set to 0.7, and the weighting coefficient of the third diameter can be set to 0.3 to focus on the stability of the current size.

[0026] The grading judgment value is then compared with a preset grading judgment value range. If the grading judgment value exceeds the maximum value of the preset grading judgment value range, a first-level filtering signal is generated; if the grading judgment value is within the preset grading judgment value range, a second-level filtering signal is generated; if the grading judgment value does not exceed the minimum value of the preset grading judgment value range, a third-level filtering signal is generated. The above signals are sent to the dynamic allocation unit 3 and the intelligent monitoring terminal 5 through the data transmission line.

[0027] The dynamic allocation unit 3 determines the appropriate grading strategy for the high-purity zirconia beads based on the received screening signals. A first-level screening signal corresponds to a high-speed grading strategy, a second-level screening signal to a medium-speed grading strategy, and a third-level screening signal to a low-speed grading strategy. The dynamic allocation unit 3 contains multiple grading chambers, each equipped with an independent drive unit and conveyor belt. The drive unit adjusts the conveyor belt speed according to the screening signals, thereby achieving grading operations at different speeds. After grading is completed, the dynamic allocation unit 3 sends the grading information to the intelligent monitoring terminal 5, which integrates the received information and displays the grading results.

[0028] The quality assessment unit 4 monitors the grading process through the parameter tracking feedback module 6. The parameter tracking feedback module 6 collects key parameters such as vibration frequency, conveyor belt speed, and grading chamber pressure during the grading process, and labels them as vibration detection values, conveyor speed detection values, and chamber pressure detection values, respectively. The parameter tracking feedback module 6 compares these values ​​with preset vibration detection value ranges, preset conveyor speed detection value ranges, and preset chamber pressure detection value ranges. If any parameter is outside its preset range, the grading process is deemed unreasonable, and relevant information is sent to the quality assessment unit 4. If all parameters are within their preset ranges, the parameter tracking feedback module 6 further calculates the vibration characteristic value, conveyor characteristic value, and chamber pressure characteristic value. Specifically, the parameter tracking feedback module 6 calculates the difference between the vibration detection value and the median of the preset vibration detection value range and takes the absolute value to obtain the vibration characteristic value; similarly, it calculates the conveyor characteristic value and chamber pressure characteristic value. Subsequently, the parameter tracking feedback module 6 performs a weighted summation of the vibration characteristic value, conveyor characteristic value, and chamber pressure characteristic value to obtain the parameter tracking value. The parameter tracking value is compared with the preset parameter tracking threshold. If the parameter tracking value exceeds the preset parameter tracking threshold, it is determined that the current state is in an unreasonable classification state.

[0029] When the quality assessment unit 4 determines that the current state is classified as irrationally unreasonable, it starts a timer to record the duration of each instance of irrationality. The sum of all irrationality durations within a unit of time is marked as the irrationality detection value. The quality assessment unit 4 compares the irrationality detection value with a preset irrationality detection threshold. If the irrationality detection value exceeds the preset threshold, a high-risk signal is generated. If the irrationality detection value does not exceed the threshold, the quality assessment unit 4 further counts the number of irrationality durations exceeding the preset threshold within a unit of time and marks them as irrationality risk values. Simultaneously, the quality assessment unit 4 marks the irrationality duration with the largest value within a unit of time as the irrationality amplitude value. The quality assessment value is obtained by weighted summation of the irrationality detection value, the irrationality risk value, and the irrationality amplitude value. The quality assessment value is compared with a preset quality assessment threshold. If the quality assessment value exceeds the preset quality assessment threshold, a graded high-risk signal is generated; if the quality assessment value does not exceed the preset quality assessment threshold, a graded low-risk signal is generated.

[0030] The grading impact assessment module 7 is communicatively connected to the quality assessment unit 4 for further analysis of the grading low-risk signals. The grading impact assessment module 7 collects equipment information associated with the grading of high-purity zirconia beads and marks the corresponding equipment as impact object i, where i is a natural number greater than 1. The grading impact assessment module 7 collects the time elapsed between the installation date and the current date of impact object i and marks it as the installation duration, comparing the installation duration with a corresponding preset installation duration threshold. If the installation duration exceeds the corresponding preset installation duration threshold, impact object i is marked as an abnormal object. If the installation duration does not exceed the corresponding preset installation duration threshold, the grading impact assessment module 7 further collects the total duration that impact object i has been in operation throughout the historical period and marks it as the working duration, comparing the working duration with a corresponding preset working duration threshold. If the working duration exceeds the corresponding preset working duration threshold, impact object i is marked as an abnormal object. If there are abnormal objects among the equipment associated with the grading of high-purity zirconia beads, the grading impact assessment module 7 generates a grading impact alarm signal.

[0031] If no abnormal objects are found in the equipment associated with the grading of high-purity zirconia beads, the grading impact assessment module 7 further calculates the installation time value and the operating time value. Specifically, the grading impact assessment module 7 marks the ratio of the installation time of affected object i to the corresponding preset installation time threshold as the installation time value, and marks the average of the installation time values ​​of all equipment as the installation time value. Similarly, the grading impact assessment module 7 marks the ratio of the operating time of affected object i to the corresponding preset operating time threshold as the operating time value, and marks the average of the operating time values ​​of all equipment as the operating time value. In addition, the grading impact assessment module 7 traces back from the current time and sets a detection period, collects the number of times the grading process cannot be carried out normally due to equipment failure within the detection period, and calculates the ratio of this number to the total duration of the grading process within the detection period to obtain the operational failure value. By performing a weighted summation of the installation time value, the operating time value, and the operational failure value, the grading impact characteristic value is obtained. The graded impact feature value is compared with the preset graded impact feature threshold. If the graded impact feature value exceeds the preset graded impact feature threshold, a graded impact alarm signal is generated; if the graded impact feature value does not exceed the preset graded impact feature threshold, a graded impact safety signal is generated.

[0032] In practical applications, this system can be deployed at the end of a high-purity zirconia bead production line for automated screening and grading of the produced zirconia beads. For example, after a batch of high-purity zirconia beads is removed from the sintering furnace, it is conveyed to the size detection unit 1 via a conveyor belt for diameter measurement. The size detection unit 1 transmits the measurement data to the grading judgment unit 2, which generates a screening signal based on the measurement data and sends it to the dynamic allocation unit 3. The dynamic allocation unit 3 adjusts the conveyor belt speed in the grading chamber according to the screening signal, and after completing the grading operation, sends the grading information to the intelligent monitoring terminal 5. Throughout the process, the parameter tracking feedback module 6 monitors key parameters in the grading process in real time and sends relevant information to the quality assessment unit 4 for analysis. If the quality assessment unit 4 generates a high-risk grading signal, the intelligent monitoring terminal 5 issues a warning to prompt the operator to conduct an inspection. If the quality assessment unit 4 generates a low-risk grading signal, the grading impact assessment module 7 further analyzes potential hazards in the grading process and generates alarm or safety signals. Through the above process, this system can achieve efficient and accurate screening and grading of high-purity zirconia beads, meeting the stringent requirements of the high-end market for product quality consistency. To enable those skilled in the art to fully understand and implement this invention, the specific implementation principles of this invention are further explained below in conjunction with specific application scenarios.

[0033] In the actual production line, after high-purity zirconia beads are removed from the sintering furnace, they are conveyed to the detection area of ​​the size detection unit 1 via a conveyor belt. The high-precision optical sensor in the size detection unit 1 is installed above the conveyor belt. Its core principle is based on the photoelectric effect, collecting the contour information of the zirconia beads by emitting light and receiving reflected signals. When the zirconia beads pass under the sensor, the changes in the photoelectric signal are recorded in real time, and these signals are converted into diameter measurements using an internal algorithm. At this time, the first diameter and the second diameter correspond to the measurement data of the current time node and the adjacent previous time node, respectively, and the change between the two is calculated as the third diameter. After receiving the above data, the grading and judgment unit 2 generates a grading and judgment value through a weighted summation operation and compares it with a preset range. If the grading and judgment value exceeds the maximum value, a first-level screening signal is generated; if it is within the range, a second-level screening signal is generated; if it is below the minimum value, a third-level screening signal is generated. These signals are transmitted to the dynamic allocation unit 3 and the intelligent monitoring terminal 5 via data transmission lines.

[0034] The dynamic allocation unit 3 adjusts the operating state of the grading chamber based on the received screening signals. For example, a first-level screening signal triggers a high-speed grading strategy, in which the drive device in the grading chamber accelerates the conveyor belt to quickly complete the grading operation; a second-level screening signal corresponds to a medium-speed grading strategy, where the drive device maintains a moderate speed; and a third-level screening signal triggers a low-speed grading strategy to ensure a more precise grading process. After grading is completed, the dynamic allocation unit 3 feeds back the grading results to the intelligent monitoring terminal 5, which integrates all information and presents the final grading results on the display interface.

[0035] Throughout the grading process, the parameter tracking feedback module 6 continuously monitors key parameters, including vibration frequency, conveyor belt speed, and grading chamber pressure. These parameters are labeled as vibration detection values, conveyor speed detection values, and chamber pressure detection values, and are compared with preset ranges in real time. If any parameter exceeds the range, the current grading is deemed unreasonable, and relevant information is sent to the quality assessment unit 4. If all parameters are within the range, the parameter tracking feedback module 6 further calculates vibration characteristic values, conveyor characteristic values, and chamber pressure characteristic values. Specifically, the vibration characteristic value is obtained by taking the absolute value of the difference between the vibration detection value and the value within the preset vibration detection value range; the conveyor characteristic value and chamber pressure characteristic value are calculated similarly. Subsequently, these characteristic values ​​are weighted and summed to generate parameter tracking values, which are then compared with preset thresholds. If the parameter tracking value exceeds the threshold, the current grading is also deemed unreasonable.

[0036] Upon receiving the graded unreasonable status information, quality assessment unit 4 starts a timer to record the duration of each graded unreasonable event and calculates the sum of all graded unreasonable event durations within a unit of time as the graded unreasonable detection value. The graded unreasonable detection value is compared with a preset threshold. If it exceeds the threshold, a graded high-risk signal is generated; otherwise, the number and maximum value of graded unreasonable event durations are further counted and marked as the graded unreasonable risk value and graded unreasonable amplitude value, respectively. A quality assessment value is obtained through weighted summation and compared with a preset quality assessment threshold. If the quality assessment value exceeds the threshold, a graded high-risk signal is generated; otherwise, a graded low-risk signal is generated.

[0037] Upon receiving a low-risk level signal, the tiered impact assessment module 7 further analyzes the equipment status. First, it collects the equipment's installation date and operating duration, labeling them as installation duration and operating duration, respectively, and compares them with preset thresholds. If either duration exceeds the threshold, the equipment is marked as an abnormal object, and a tiered impact alarm signal is generated. If all equipment does not exceed the threshold, the installation and operating time status values ​​are calculated, and their average values ​​are used to obtain the installation and operating time analysis values. Furthermore, the tiered impact assessment module 7 traces the number of equipment failures within the detection period and calculates the operational failure value by comparing it to the total duration. A tiered impact feature value is generated through a weighted summation operation and compared with a preset threshold. If the feature value exceeds the threshold, a tiered impact alarm signal is generated; otherwise, a tiered impact safety signal is generated.

[0038] Through the above steps, this system can achieve efficient and accurate screening and grading of high-purity zirconia beads. For example, in a practical application, after a batch of zirconia beads was measured by the size detection unit 1, the grading judgment unit 2 generated a secondary screening signal, and the dynamic allocation unit 3 used a medium-speed grading strategy to complete the grading operation accordingly. At the same time, the parameter tracking feedback module 6 detected that the vibration frequency was slightly higher than the preset range, but other parameters were normal, so it was judged to be an unreasonable grading state. After further analysis, the quality assessment unit 4 generated a low-risk grading signal, and the grading impact assessment module 7 confirmed that the equipment status was normal and generated a grading impact safety signal. Finally, the intelligent monitoring terminal 5 displayed that the grading result was qualified and reminded the operator to pay attention to the slight abnormality in vibration frequency. Through this process, this system not only improves grading efficiency but also significantly enhances the consistency of product quality, meeting the stringent requirements of the high-end market for high-purity zirconia beads.

[0039] All content not described in detail in this specification belongs to existing technology known to those skilled in the art, and the model parameters of each electrical component are not specifically limited; conventional equipment can be used. Electrical control components not mentioned in this technical solution are not shown in the figures and will not be described further. The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automatic screening and grading system for high-purity zirconia beads, characterized in that: Including size The system includes a detection unit (1), a grading and judgment unit (2), a dynamic allocation unit (3), a quality assessment unit (4), and an intelligent monitoring terminal (5). The size detection unit (1) measures the diameter of the high-purity zirconia beads in real time using a high-precision optical sensor and sends the measurement data to the grading and judgment unit (2). The grading and judgment unit (2) calculates the current size characteristic value of the high-purity zirconia beads based on the measurement data, and generates a first-level screening signal, a second-level screening signal or a third-level screening signal accordingly, and sends the first-level screening signal, the second-level screening signal or the third-level screening signal to the dynamic allocation unit (3) and the intelligent monitoring terminal (5); The dynamic allocation unit (3) determines the grading strategy currently matched by the high-purity zirconia beads based on the corresponding screening signal. The first-level screening signal, the second-level screening signal and the third-level screening signal correspond to the high-speed grading strategy, the medium-speed grading strategy and the low-speed grading strategy, respectively. Based on the matched grading strategy, it controls the grading operation for the high-purity zirconia beads and sends the grading information to the intelligent monitoring terminal (5). The quality assessment unit (4) analyzes the quality risk of the grading process and generates a high-risk or low-risk grading signal, and sends the high-risk or low-risk grading signal to the intelligent monitoring terminal (5).

2. The automatic screening and grading system for high-purity zirconia beads according to claim 1, characterized in that: The specific analysis process of the grading determination unit (2) is as follows: the diameter measurement value at the current time node and the diameter measurement value at the adjacent previous time node are obtained and marked as the first diameter and the second diameter, and the change of the second diameter relative to the first diameter is marked as the third diameter; the grading determination value is obtained by weighted summation of the first diameter and the third diameter, and the grading determination value is compared with the preset grading determination value range; if the grading determination value exceeds the maximum value of the preset grading determination value range, a first-level screening signal is generated; if the grading determination value is within the preset grading determination value range, a second-level screening signal is generated; if the grading determination value does not exceed the minimum value of the preset grading determination value range, a third-level screening signal is generated.

3. The automatic screening and grading system for high-purity zirconia beads according to claim 1, characterized in that: The quality assessment unit (4) is connected to the parameter tracking and feedback module (6). The parameter tracking and feedback module (6) tracks and monitors the grading process of high-purity zirconia beads, analyzes the deviation of the grading execution to determine whether it is in an unreasonable grading state, and sends the analysis and judgment information to the quality assessment unit (4) in real time.

4. The automatic screening and grading system for high-purity zirconia beads according to claim 3, characterized in that: The specific analysis process of the parameter tracking feedback module (6) includes: collecting the vibration frequency during the grading process of high-purity zirconia beads and marking it as the vibration detection value; collecting the conveyor belt speed and grading chamber pressure and marking them as the conveyor speed detection value and the chamber pressure detection value, respectively; comparing the vibration detection value, conveyor speed detection value and chamber pressure detection value with the preset vibration detection value range, preset conveyor speed detection value range and preset chamber pressure detection value range, respectively; if the vibration detection value, conveyor speed detection value or chamber pressure detection value is not within the corresponding preset range, it is determined that the current grading is in an unreasonable state.

5. The automatic screening and grading system for high-purity zirconia beads according to claim 4, characterized in that: If the vibration detection value, conveying speed detection value, and cavity pressure detection value are all within their respective preset ranges, the vibration detection value is calculated by subtracting the median of the preset vibration detection value range and taking the absolute value to obtain the vibration characteristic value. Similarly, the conveying characteristic value and cavity pressure characteristic value are obtained. The parameter tracking value is obtained by weighted summation of the vibration characteristic value, conveying characteristic value, and cavity pressure characteristic value. The parameter tracking value is compared with the preset parameter tracking threshold. If the parameter tracking value exceeds the preset parameter tracking threshold, it is determined that the current state is in an unreasonable classification state.

6. The automatic screening and grading system for high-purity zirconia beads according to claim 3, characterized in that: The specific analysis process of the quality assessment unit (4) includes: timing the process from the moment the current state is determined to be categorized as unreasonable until the end of the categorized unreasonable state, thereby obtaining the duration of a single instance of categorized unreasonableness; marking the sum of all single instances of categorized unreasonableness within a unit of time as the categorized unreasonableness detection value; comparing the categorized unreasonableness detection value with a preset categorized unreasonableness detection threshold; if the categorized unreasonableness detection value exceeds the preset categorized unreasonableness detection threshold, generating a categorized high-risk signal; if the categorized unreasonableness detection value does not exceed the preset categorized unreasonableness detection threshold, then comparing the single instance duration of categorized unreasonableness with the preset categorized unreasonableness single instance duration threshold. The system compares numerical values ​​to count the number of instances of unreasonable duration exceeding a preset threshold within a unit of time and marks them as unreasonable risk values. It also marks the instance with the largest unreasonable duration within a unit of time as an unreasonable amplitude value. A quality assessment value is calculated by weighted summation of the unreasonable detection value, the unreasonable risk value, and the unreasonable amplitude value. This quality assessment value is then compared with a preset quality assessment threshold. If the quality assessment value exceeds the threshold, a high-risk signal is generated; otherwise, a low-risk signal is generated.

7. The automatic screening and grading system for high-purity zirconia beads according to claim 6, characterized in that: The quality assessment unit (4) is connected to the graded impact assessment module (7). The quality assessment unit (4) sends the graded low-risk signal to the graded impact assessment module (7). When the graded impact assessment module (7) receives the graded low-risk signal, it analyzes the potential graded hidden dangers of the high-purity zirconia beads and generates a graded impact alarm signal or a graded impact safety signal accordingly. The graded impact alarm signal or graded impact safety signal is then sent to the intelligent monitoring terminal (5).

8. The automatic screening and grading system for high-purity zirconia beads according to claim 7, characterized in that: The specific analysis process of the graded impact assessment module (7) is as follows: Collect the equipment associated with the grading of high-purity zirconia beads, mark the corresponding equipment as the affected object i, and i is a natural number greater than 1; collect the time between the installation date of affected object i and the current date and mark it as the installation time; compare the installation time with the corresponding preset installation time threshold; if the installation time exceeds the corresponding preset installation time threshold, mark affected object i as an abnormal object; if the installation time does not exceed the corresponding preset installation time threshold, mark the total time that affected object i has been in working state in the historical stage as the working time; compare the working time with the corresponding preset working time threshold; if the working time exceeds the corresponding preset working time threshold, mark affected object i as an abnormal object; if there is an abnormal object among the equipment associated with the grading of high-purity zirconia beads, generate a graded impact alarm signal.

9. The automatic screening and grading system for high-purity zirconia beads according to claim 8, characterized in that: If there are no abnormal objects in the equipment associated with the grading of high-purity zirconia beads, the ratio of the installation time of affected object i to the corresponding preset installation time threshold is marked as the installation time value, and the average of the installation time values ​​of all equipment is marked as the installation time analysis value. The ratio of the working time of affected object i to the corresponding preset working time threshold is marked as the working time value, and the average of the working time values ​​of all equipment is marked as the working time analysis value. Furthermore, starting from the current moment and tracing back to the beginning of the detection period, the number of times the grading process cannot proceed normally due to equipment failure within the detection period is collected, and this number is compared with the total grading process time within the detection period to obtain the operational failure value. The grading impact characteristic value is obtained by weighted summation of the installation time analysis value, working time value, and operational failure value. The grading impact characteristic value is then numerically compared with the preset grading impact characteristic threshold. If the grading impact characteristic value exceeds the preset grading impact characteristic threshold, a grading impact alarm signal is generated; if the grading impact characteristic value does not exceed the preset grading impact characteristic threshold, a grading impact safety signal is generated.

10. The automatic screening and grading system for high-purity zirconia beads according to claim 1, characterized in that: The dynamic allocation unit (3) is equipped with multiple grading chambers. Each chamber is equipped with an independent drive device and a conveyor belt. The drive device adjusts the speed of the conveyor belt according to the screening signal to achieve grading operation at different speeds.

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