Label printer cutting control method and system, product and medium

Abstract

The invention discloses a label printer cutting control method and system, a product and a medium. The method comprises the following steps of: quantifying a single cutting load by performing time integration on cutting force in real-time cutting, and accumulating the single cutting load; dynamically tracking a recent load state by utilizing a load sliding average value, and starting a tool changing verification program when the real-time load is obviously reduced compared with the average value; whether the load can be stably maintained at a low position or not is determined in subsequent multiple cutting, and the average load at the stage is finally compared with a physical reference value representing a brand new cutter; only when the stable low value of the load is consistent with the new tool reference, real tool changing operation is confirmed, accumulated abrasion is reset, and tool changing early warning is given out when the accumulated load value reaches an early warning threshold value. By implementing the technical scheme provided by the invention, the accuracy of cutter maintenance prompt is improved.

Description

Technical Field

[0001] This application relates to the general field of control systems, and more particularly to a label printer cutting control method, system, product, and medium. Background Technology

[0002] Currently, label printers, as data output and identification devices, are increasingly widely used in logistics warehousing, smart retail, and industrial automation. Ensuring that label printers, especially their core consumable parts like the cutter, can consistently provide high-quality cutting results is crucial for maintaining production and management efficiency.

[0003] In related technologies, to effectively manage the lifespan of the cutting blade, a built-in sensor monitors the peak current of the motor driving the blade in real time during each cutting stroke. The theoretical basis of this approach is that as the cutting blade wears down, its cutting resistance increases, requiring the motor to output greater torque, which translates into a higher peak operating current. The system pre-calibrates a current reference value for a new blade; when the subsequently monitored peak current consistently exceeds this reference value by a certain preset percentage, a maintenance warning is triggered.

[0004] However, when the printer switches its task from cutting a high-resistance material (such as thick PET synthetic labels) to a low-resistance material (such as ordinary coated paper), the overall cutting load drops drastically. At this point, even if the cutter itself is severely worn, the peak motor current generated when cutting the low-resistance material may plummet to a level far below the initial baseline set for the high-resistance material. When this peak drop is observed, it's difficult to distinguish whether it's due to a material change or a genuine cutter replacement, potentially leading to a misinterpretation of material change as cutter maintenance and reducing the accuracy of maintenance alerts. Summary of the Invention

[0005] This application provides a label printer cutting control method, system, product, and media for improving the accuracy of cutter maintenance prompts.

[0006] The first aspect of this application provides a label printer cutting control method, the method comprising: During real-time cutting operations, cutting duration and cutting force data are acquired. The cutting force data acquired within the cutting duration is integrated over time to obtain the real-time single-cut load index. This real-time single-cut load index is then added to the currently stored cumulative load index to obtain the real-time cumulative load index. The load index queue for storing historical single-cut load indices for a preset number of times is updated, with the real-time single-cut load index being enqueued from the tail and the first-ranked single-cut load index being dequeued. When the load decline rate exceeds a preset reset decline rate threshold, the current cumulative load index is stored as a historical snapshot in the temporary storage area, and the initial... A verification counter with an initial value of zero is used. During the cutting operation with a preset number of verifications after the verification counter is started, the real-time single-cut verification load index corresponding to each cut is obtained. If the real-time single-cut verification load index is lower than the load sliding average value before the verification counter is started, the count value of the verification counter is incremented by one. After completing the cutting operation with a preset number of verifications, if the final count value of the verification counter is equal to the preset number of verifications and the verification average load index is equal to or less than the preset physical reference value of the cutter, the cumulative load index is set to zero. When the cumulative load index reaches the preset wear warning threshold, a cutter maintenance warning message is issued.

[0007] In the above embodiments, a multi-level verification mechanism is triggered by dynamically capturing the load drop rate by establishing a load sliding average. By activating a verification counter, the stability of the new working state is continuously confirmed during subsequent cuts, ensuring the load remains consistently low. After stability is confirmed, the verification average load index of this new state is compared with a preset physical reference value representing a brand-new cutter. Therefore, even if material replacement causes a sudden drop in load, the cumulative index will not be incorrectly reset as long as the stabilized load value fails to reach the new cutter reference value. This distinguishes between material replacement and actual cutter maintenance, solving the problem of maintenance management failure caused by the inability to differentiate event types in related technologies.

[0008] In conjunction with some embodiments of the first aspect, in some embodiments, after completing a preset number of verification operations, if the final count value of the verification counter is equal to the preset number of verifications and the average verification load index is equal to or less than the preset physical reference value of the cutter, then after setting the cumulative load index to zero, the method further includes: In the continuous cutting operation with a preset number of slow-release cycles, the real-time slow-release single-cut load index is continuously acquired, the load index queue is updated, and the latest load sliding average is calculated. When the real-time slow-release single-cut load index exceeds the preset rebound ratio of the load sliding average value before the start verification counter, the current cumulative load index is set to the value corresponding to the historical snapshot, and the data in the load index queue is restored to the state before the start verification counter.

[0009] In the above embodiments, after the wear index is reset, a slow-release observation period is established and pre-stored historical snapshots are used as a basis for retrospection, thus possessing the ability to self-correct misjudgments. Even if a false tool change event caused by complex working conditions such as temporary material replacement deceives the previous judgment, once the load rebounds to a high level close to the historical snapshot during the observation period, the erroneous reset operation can be undone, thereby providing double insurance for the accuracy of wear accumulation and enhancing the robustness of the entire control scheme.

[0010] In conjunction with some embodiments of the first aspect, in some embodiments, after updating the load index queue storing historical single-cut load indices for a preset number of times, enqueuing the real-time single-cut load index from the tail of the queue and dequeuing the single-cut load index ranked at the head of the queue, the method further includes: When the load decline rate first reaches the reset decline rate threshold, retrieve the continuous load data collected in the most recent cutting action that covers the entire cutting process to obtain the most recent instantaneous load shape curve; when the peak value of the most recent instantaneous load shape curve is less than the historical baseline value and the difference between it and the historical baseline value is greater than the preset difference threshold, reset the cumulative load index to zero.

[0011] In the above embodiment, when the first sudden drop in load is detected, the instantaneous load pattern curve of the most recent cut is immediately retrieved and analyzed, elevating the judgment dimension from a single integral value to a curve pattern that reflects process details. Furthermore, by directly comparing the difference between the curve peak and the historical baseline, the physical principle that the peak force of a new tool during cutting is necessarily much lower than the average load under the wear state of an old tool is utilized. This allows for a high-confidence feature-based judgment at the instant the event occurs, eliminating a lengthy multi-step verification process, improving the real-time performance and decision-making efficiency of tool change event identification, and achieving rapid and accurate management of the cutting tool status.

[0012] In conjunction with some embodiments of the first aspect, in some embodiments, after retrieving continuous load data covering the entire cutting process collected in the most recent cutting action to obtain the most recent instantaneous load profile curve when the load descent rate first reaches the reset descent rate threshold, the method further includes: When the peak value of the most recent instantaneous load pattern curve is less than the historical baseline value and the difference between the two values ​​is greater than a preset difference threshold, the real-time cutting fingerprint parameter is obtained for the net peak value of the most recent instantaneous load pattern curve. When the difference between the real-time cutting fingerprint parameter and the historical cutting fingerprint parameter is within the preset cutting fingerprint error threshold range, the cumulative load index is reset to zero.

[0013] In the above embodiments, by comparing the real-time cutting fingerprint, which reflects the physical characteristics of the cutter, with the historical cutting fingerprint parameters learned and stored by the system after the last cutter change, an authentication procedure is added to each cutter change operation. This method ensures that wear reset is only performed when the dynamic cutting characteristics of the new cutter are completely consistent with the expected standard model, eliminating interference caused by changing different types of cutters or consumables and improving the accuracy of maintenance management.

[0014] In conjunction with some embodiments of the first aspect, in some embodiments, after completing a preset number of verification operations, if the final count value of the verification counter is equal to the preset number of verifications and the average verification load index is equal to or less than the preset physical reference value of the cutter, then after setting the cumulative load index to zero, the method further includes: If the final count is less than the preset number of verifications, then read the historical snapshot from the temporary storage area and set the cumulative load index to the value corresponding to the historical snapshot.

[0015] In the above embodiments, by pre-storing historical snapshots before starting verification, if subsequent multi-step verification processes ultimately fail due to unstable load (i.e., the count value does not meet the standard), the cumulative wear index can be instantly rolled back to the accurate value before the event occurred using this snapshot. This ensures that misjudgments triggered by temporary fluctuations in operating conditions, such as temporary material replacement, can be completely eliminated, thereby guaranteeing the continuity and accuracy of wear data, avoiding life calculation errors caused by temporary event interference, and improving the reliability of the entire life management system.

[0016] In conjunction with some embodiments of the first aspect, in some embodiments, before storing the current cumulative load index as a historical snapshot in the temporary storage area and starting the verification counter with an initial value of zero when the load decline rate is greater than a preset reset decline rate threshold, the method further includes: After each cutting operation, the time interval between the end of the current cutting and the arrival of the next cutting command is recorded and recorded as the instantaneous cutting interval. The moving average of the instantaneous cutting intervals with the most recent preset rhythm threshold is calculated in real time to obtain the average working rhythm parameter. Combined with the preset rhythm-load compensation curve, the average working rhythm is mapped to the thermal effect compensation factor. The thermal effect compensation factor is added to the real-time single cutting load index to correct the real-time single cutting load index and replace the real-time single cutting load index for calculating the load drop rate.

[0017] In the above embodiments, the physical phenomenon of heat accumulation due to high-frequency operation, which leads to a decrease in load readings, is identified and quantified in advance. By performing thermal effect correction on the original load data before judging the load drop, interference from the operating rhythm is removed from the signal source, thereby distinguishing whether it is a real tool change, reducing the misjudgment rate caused by changes in production rhythm, and improving the accuracy and robustness of wear condition assessment.

[0018] In conjunction with some embodiments of the first aspect, in some embodiments, before storing the current cumulative load index as a historical snapshot in the temporary storage area and starting the verification counter with an initial value of zero when the load decline rate is greater than a preset reset decline rate threshold, the method further includes: Obtain the real-time operating voltage of the cutter motor and calculate the voltage deviation rate between the real-time operating voltage of the cutter motor and the preset standard reference voltage. When the real-time operating voltage of the cutter motor is lower than the preset standard reference voltage, adjust the load index downward according to the voltage deviation rate. When the real-time operating voltage of the cutter motor is higher than the preset standard reference voltage, adjust the load index upward according to the voltage deviation rate to obtain the corrected real-time single-cut load index, which is then used to replace the real-time single-cut load index for calculating the load drop rate.

[0019] In the above embodiments, the real-time operating voltage of the cutter motor is included in the monitoring, identifying and quantifying grid fluctuations as a key source of interference. Before making any wear assessment, the original load data is dynamically compensated and corrected based on the real-time voltage deviation rate. This is equivalent to building a filter at the data source, eliminating falsely high or low load readings caused by voltage instability, and improving the accuracy of the entire wear assessment system.

[0020] In a second aspect, embodiments of this application provide a label printer cutting control system, which includes: one or more processors and a memory; the memory is coupled to the one or more processors, and the memory is used to store computer program code, which includes computer instructions, and the one or more processors call the computer instructions to cause the label printer cutting control system to perform the method described in the first aspect and any possible implementation thereof.

[0021] Thirdly, embodiments of this application provide a computer program product containing instructions that, when the computer program product is run on a label printer cutting control system, cause the label printer cutting control system to perform the method described in the first aspect and any possible implementation thereof.

[0022] Fourthly, embodiments of this application provide a computer-readable storage medium including instructions that, when executed on a label printer cutting control system, cause the label printer cutting control system to perform the method described in the first aspect and any possible implementation thereof.

[0023] Understandably, the label printer cutting control system provided in the second aspect, the computer program product provided in the third aspect, and the computer storage medium provided in the fourth aspect are all used to execute the label printer cutting control method provided in the embodiments of this application. Therefore, the beneficial effects they can achieve can be referred to the beneficial effects in the corresponding methods, and will not be repeated here.

[0024] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages: This application dynamically captures the load drop rate by establishing a load sliding average, thereby triggering a multi-level verification mechanism. By activating a verification counter, the load is continuously checked to ensure it remains stable at a low level during subsequent cuts, confirming the stability of the new working state. After stability is confirmed, the verification average load index of this new state is compared with the preset physical reference value of the new cutter. Therefore, even if a sudden drop in load occurs due to material replacement, as long as the stabilized load value fails to reach the new cutter reference, the cumulative index will not be incorrectly reset. This distinguishes between material replacement and actual cutter maintenance, solving the problem of maintenance management failure caused by the inability to distinguish event types in existing technologies.

[0025] After resetting the wear index, this application establishes a slow-release observation period and utilizes pre-stored historical snapshots as a retrospective basis, thus possessing the ability to self-correct misjudgments. Even if a false tool change event caused by complex operating conditions such as temporary material replacement deceives the previous judgment, once the load rebounds to a high level close to the historical snapshot during the observation period, the erroneous reset operation can be reversed. This provides double insurance for the accuracy of wear accumulation and enhances the robustness of the entire control scheme.

[0026] 3. This application compares the real-time cutting fingerprint, which reflects the physical characteristics of the cutting tool, with the historical cutting fingerprint parameters learned and stored by the system after the last tool change. This adds an authentication procedure to each tool change operation. This method ensures that wear reset is only performed when the dynamic cutting characteristics of the new tool are completely consistent with the expected standard model, eliminating interference caused by changing different types of tools or consumables and improving the accuracy of maintenance management. Attached Figure Description

[0027] Figure 1 This is a flowchart illustrating a label printer cutting control method in an embodiment of this application; Figure 2 This is another flowchart illustrating the label printer cutting control method in the embodiments of this application; Figure 3 These are comparison images of instantaneous cutting load fingerprints under different working conditions as described in Embodiment 2 of this application; Figure 4This is a schematic diagram of an exemplary hardware structure of the label printer cutting control system in an embodiment of this application. Detailed Implementation

[0028] The terminology used in the following embodiments of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. As used in the specification and appended claims of this application, the singular expressions “a,” “an,” “the,” “the,” “the,” and “this” are intended to include the plural expressions as well, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in this application refers to and includes any or all possible combinations of one or more of the listed items.

[0029] Hereinafter, the terms "first" and "second" are used for descriptive purposes only and should not be construed as implying or suggesting relative importance or implicitly indicating the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature, and in the description of the embodiments of this application, unless otherwise stated, "multiple" means two or more.

[0030] In related technologies, cumulative cutting load is used to quantify the wear of cutting tools. When determining whether a user has performed tool replacement maintenance, an intuitive but flawed method is to monitor whether the cutting load has dropped significantly. The logic behind this method is that the cutting resistance of a new tool is much lower than that of an old tool. However, this method ignores the potential changes in the operating conditions themselves. For example, when the machining task changes from a high-resistance hard material to a low-resistance soft material, the cutting load will also drop sharply. In this case, observing a sudden drop in load might mistakenly lead to the assumption that the cutting tool has been replaced, and the cumulative wear value is reset to zero, when in fact the old tool is still in service. This misinterpretation of changes in operating conditions as equipment maintenance results in inaccurate tool life management.

[0031] In this embodiment, when the load drop rate is detected to exceed a threshold, the system does not immediately reset; instead, a multi-level verification mechanism is initiated. First, it does not rely on a single load drop but activates a verification counter to continuously confirm whether the load remains stable at a low level during subsequent cutting operations. This aims to confirm the persistence of the new working state, thereby eliminating short-term fluctuations. More importantly, after confirming the new state's stability, the verification average load index under this stable state is compared with a preset cutting tool physical benchmark value representing the physical characteristics of a new tool. Therefore, even if a material change leads to a stable load drop, a reset will not be performed as long as the load value fails to reach the benchmark level of the new tool. This strategy, combining stability verification with physical benchmark comparison, gives the system the ability to distinguish between actual tool changes and material changes, solving the problem of misjudgment and ensuring the accuracy of wear tracking.

[0032] Figure 1 This is a flowchart illustrating the label printer cutting control method used in the embodiments of this application, including the following steps: S101. Acquire cutting duration and cutting force data during real-time cutting operation.

[0033] In this context, the real-time cutting operation, for printers requiring manual triggering, refers to an independent electromechanical cycle initiated by the operator on demand. In this scenario, after printing, the printer holds the label media in the cut-ready position and enters a waiting state. The cycle begins with a specific physical action by the operator, such as pressing a dedicated cutter button on the control panel, generating an external trigger signal that constitutes the cutting command received by the main control unit. Upon receiving this command, the cutter module is driven to perform a complete cutting and repositioning action, ending when the cutter returns to its mechanical origin. For devices using direct manual control of the cutter, the starting point of the real-time cutting operation cycle is the instant the operator's hand begins to apply force to the control mechanism, causing displacement; the ending point is the moment the mechanism completes a full stroke (e.g., the lever is pressed to the bottom), driving the blade to completely cut the label media; the cutting duration represents the total time consumed by the complete cutting action; and the cutting force data refers to the data obtained by continuous sampling at a fixed high frequency by a sensor throughout the entire cutting duration, indirectly or directly reflecting the physical resistance experienced by the cutter at the sampling instant.

[0034] Specifically, when the printer's main control unit (MCU) receives a cutting command, it immediately starts a high-precision hardware timer and begins data acquisition. The source of this cutting command varies depending on the device type: for automatic cutting models, the command is automatically generated by the firmware when printing conditions are met; for manually triggered electromechanical models, the command originates from the external electrical signal generated by the user pressing the cutter button. For these two types of motor-driven models, after the command is triggered, the MCU sends a control signal (such as a PWM signal) to the cutter driver chip to move the motor. Simultaneously, a current sensor (such as a low-resistance precision shunt resistor) connected in series with the motor power supply circuit starts working. Its output analog voltage signal is amplified and filtered, then periodically sampled, quantized, and stored in the RAM buffer by the MCU's analog-to-digital converter (ADC). For purely mechanical cutting devices that are directly controlled manually, the cutting command can be defined as the event where the reading of a force sensor mounted on its load-bearing structure first exceeds a preset noise threshold. This event also triggers the hardware timer and data acquisition process, but the cutting force data comes directly from the force sensor, rather than the motor current. At the end of the cutting action—for motor-driven types, the limit switch or position sensor reports the cutter returning to its original position; for manually controlled types, the displacement sensor reports that the mechanism has reached the end of its stroke—the MCU stops the hardware timer and terminates data acquisition. At this point, the timer reading is the cutting duration, and the complete data sequence stored in the RAM buffer is the cutting force data for this operation, depicting the load change curve of the entire cutting process from blade entry, stable cutting to blade exit.

[0035] S102. Integrate the cutting force data acquired during the cutting time over time to obtain the real-time single cutting load index.

[0036] Among them, the real-time single-cut load index refers to a single scalar value obtained by time integration calculation, which represents the overall load of a single cutting operation.

[0037] Specifically, after confirming that a complete cutting force data sequence has been acquired, the main control unit (MCU) reduces the original data sequence stored in the RAM cache in S101 into a single index that can stably characterize the effort required for the cut. The theoretical basis is that factors such as blade wear, material toughness, thickness, and cutting speed do not only affect a single moment in the cutting process but collectively determine the energy consumption of the entire process. By integrating the force data over time, multiple dimensions of morphological information, such as peak size and peak width (duration), can be coupled into a comprehensive index, thus smoothing out the interference of instantaneous data spikes caused by electrical noise or mechanical vibration, resulting in a robust load characteristic value. In digital signal processing, this integration process is typically discretized into a single summation operation: the processor iterates through each force sample value Fᵢ in the data sequence, multiplies it by the sampling time interval Δt (i.e., the reciprocal of the sampling frequency), and then sums the areas of all these tiny rectangles, ultimately obtaining the real-time single-cut load index for this cut.

[0038] Understandably, higher-order numerical integration algorithms, such as Simpson's rule, can be used to further improve integration accuracy, or frequency domain analysis based on Fourier transform can be introduced to calculate the energy within a specific frequency band as the load index, in order to adapt to different accuracy and computational resource requirements. No limitation is made here.

[0039] S103. Add the real-time single-cut load index to the currently stored cumulative load index to obtain the real-time cumulative load index.

[0040] The currently stored cumulative load index is a core variable maintained in non-volatile memory (such as Flash or EEPROM) or power-loss protection RAM. This variable is used to continuously record the total workload borne by the cutter since the last count value of the cutter was reset (e.g. after a new cutter was replaced). It is a direct basis for assessing the long-term wear of the cutter. The real-time cumulative load index is the updated total cumulative load value obtained by adding the currently stored cumulative load and the real-time single-cut load index.

[0041] Specifically, after receiving the real-time single-cut load index, the main control unit (MCU) immediately updates the cumulative load index. First, it reads the current cumulative load index value from memory, then adds it to the new real-time single-cut load index in the CPU's arithmetic logic unit (ALU), and finally writes the sum back to the original memory address, overwriting the old value. The theoretical basis lies in modeling the physical wear process of the cutting tool as a linear, discrete cumulative process. It assumes that each cut causes a certain amount of irreversible wear to the tool, and this wear is proportional to the energy consumed in that cut (i.e., the single-cut load index). By continuously accumulating each tiny amount of wear, the entire lifecycle of the tool, from a brand-new state to a scrapped state, is macroscopically tracked.

[0042] S104. Update the load index queue of the historical single-cut load index with a preset number of storage times, enqueue the real-time single-cut load index from the tail of the queue and dequeue the single-cut load index ranked at the head of the queue.

[0043] The load index queue is a data structure in system memory (RAM) with a first-in, first-out (FIFO) characteristic. It allocates a fixed-size storage area specifically for storing the real-time single-cut load index of the most recent preset number of times (e.g., the most recent 100 times). Updating refers to the two sub-actions of enqueueing and dequeueing the contents of the load index queue. Enqueueing from the tail means adding the latest data item (i.e., the single-cut load index calculated this time) to the end of the queue. Dequeueing the single-cut load index ranked at the head of the queue means removing the load index that has existed for the longest time in the queue, that is, the load index representing the earliest cut, from the head of the queue.

[0044] Specifically, after updating the cumulative load, the main control unit (MCU) maintains the load index queue. This queue is usually implemented in software using a circular buffer to achieve efficient space utilization and O(1) time complexity for enqueue / dequeue operations. When a new real-time single-cut load index arrives, the processor writes it to the memory location pointed to by the current tail pointer and then moves the tail pointer one position to the right. At the same time, in order to keep the queue length constant (i.e., the preset number, which is an optimal value obtained through empirical calibration based on a large amount of experimental data and the balance requirements between response sensitivity and data stability in specific application scenarios), the head pointer will also move one position to the right accordingly. This is logically equivalent to discarding the oldest data. Its core function is to build a sliding window that can reflect recent working conditions. By always keeping the cutting history data stored in the queue for the most recent period, a dynamic and sensitive load sliding average value that can reflect the current state of the cutter or recent changes in the cutting material can be calculated, thus avoiding the disadvantage of using a fixed reference value that cannot adapt to changes in working conditions.

[0045] In some embodiments, the updating and management of the load index queue can be achieved in several ways: Optionally, a dual-queue mechanism can be used to distinguish between short-term fluctuations and long-term trends. Specifically, this includes: 1) The system simultaneously maintains a short-cycle queue (e.g., storing data from the last 20 cuts) and a long-cycle queue (e.g., storing data from the last 200 cuts) in memory; 2) The short-cycle queue is used to calculate a sensitive short-term moving average, primarily for quickly detecting events such as sudden load drops in S105; 3) The long-cycle queue is used to calculate a more stable baseline value that better represents long-term wear trends, which can be used for more macroscopic lifespan prediction or anomaly detection. When a new single load index is generated, both queues will simultaneously perform enqueue and dequeue operations.

[0046] Understandably, more complex data structures could also be used, such as a weighted queue, where newer data is given a higher weight when calculating the average; or based on the printer's operating rhythm (for example, the first cut data after a long standby period may be given a lower weight or not included in the queue), to achieve more intelligent data filtering and management, which is not limited here.

[0047] S105. When the load drop rate is greater than the preset reset drop rate threshold, the current cumulative load index is stored as a historical snapshot in the temporary storage area, and a verification counter with an initial value of zero is started.

[0048] Among them, the load sliding average is the result obtained by arithmetically averaging all values ​​in the load index queue in S104; the load drop rate is a dimensionless ratio used to quantify the decline of the current cutting load relative to the recent average level, and the calculation formula is: (load sliding average - real-time single cutting load index) / load sliding average; the preset reset drop rate threshold is a critical percentage pre-calibrated based on experience or experiments. When the load drop rate exceeds this value, it is considered that an event sufficient to cause a drastic change in the state may have occurred (such as replacing with a thinner material); the historical snapshot represents a backup of the current cumulative load index value before starting the subsequent verification procedure. It acts like a system restore point and is used to restore the state after verification failure.

[0049] After each load index calculation (S102) and queue update (S104), a conditional check is performed. Specifically, first, the load moving average is calculated from the queue data in S104. This average is then substituted into the formula with the latest real-time single-cut load index to calculate the load decline rate. The calculated decline rate is compared with a preset reset decline rate threshold. If the decline rate does not exceed the threshold, no operation is performed in this step. If the decline rate exceeds the threshold, the system enters a pending verification state and immediately performs a series of actions: First, the accumulated load index in S103 is read and completely copied to a temporary, secure storage area to form a historical snapshot; then, a variable named verification counter is started in memory and its value is set to zero.

[0050] In some embodiments, after obtaining the real-time single-cut load index and before calculating the load drop rate, a dynamic compensation mechanism based on the working rhythm can be introduced to correct the interference of the load index caused by the thermal effect of the cutting frequency change, thereby improving the accuracy of load drop detection.

[0051] First, the theoretical basis lies in the fact that during continuous cutting, the cutting blade generates heat due to friction, and the rate of heat accumulation and dissipation is closely related to the cutting frequency (i.e., the working rhythm). High-frequency continuous cutting leads to heat accumulation, which may cause local softening of the cutting blade or material, resulting in a lower cutting load; conversely, low-frequency intermittent cutting provides sufficient cooling time, potentially resulting in a higher cutting load. This load fluctuation caused by the working rhythm is not a true physical wear change of the cutting blade. If not eliminated, it will become a serious noise signal, potentially falsely triggering or masking a real load drop event.

[0052] After each cutting operation, the time interval between the end of this cutting and the arrival of the next cutting command is recorded as the instantaneous cutting interval. Since the single cutting interval may have occasional fluctuations (such as brief operator hesitation), the moving average of the most recent N instantaneous cutting intervals (where N is a preset rhythm threshold) is calculated in real time to obtain a stable average working rhythm parameter that reflects the current actual working state. An internally preset rhythm-load compensation curve is used. This curve is based on a pre-calibrated data model (which can be in the form of a lookup table, polynomial function, etc.) that describes the nonlinear relationship between the average working rhythm parameter and the load exponential offset. Using the average working rhythm parameter obtained in the previous step as input, the corresponding thermal effect compensation factor is queried or calculated through this curve. For example, a shorter average interval (fast rhythm) will map a positive compensation factor to offset the load reduction caused by heat.

[0053] Finally, the thermal effect compensation factor is algebraically added to the original real-time single-cut load index to obtain a new real-time single-cut load index after thermal effect correction. The corrected load index is considered to be a value that better represents the actual physical interaction between the cutter and the material after eliminating the influence of working rhythm variations. It replaces the original value and is used in all subsequent calculations, especially the update of the load index queue in S104 and the calculation of the load drop rate in S105, thus providing high-quality data input for the entire decision-making system.

[0054] The core advantage of the above technical steps lies in decoupling physical wear from thermal interference, thereby improving the signal-to-noise ratio of the input signal. By monitoring the operating rhythm in real time and using compensation curves to quantify and remove the interference of thermal effects on the load index, a purer load signal reflecting only true wear is obtained. This allows subsequent load drop rate calculations to identify sudden drops caused by changes in the cutting tool or material, rather than fluctuations caused by changes in the operating rhythm, thus improving the decision reliability of the entire detection system.

[0055] S106. In the cutting operation with a preset number of verifications after the verification counter is started, obtain the real-time single verification cutting load index corresponding to each cutting.

[0056] The start of the verification counter clarifies the time starting point of this step, which is after the conditions in S105 are met and executed. The preset number of verifications is a fixed, small integer, determined based on statistical confidence requirements and a large number of working condition simulation experiments. It defines the size of the subsequent verification window, i.e., how many subsequent cutting operations need to be observed to make a final judgment. Obtaining the real-time single-cut verification load index corresponding to each cut indicates that within this verification window period, for each cut, the same operation process as S101 and S102 is still performed, i.e., collecting complete force data and performing time integration. The calculated result is logically specially marked as the load index used for verification.

[0057] Specifically, after S105 is triggered, the printer does not stop working normally but continues to accept and execute cutting operations. For each subsequent cut, the number of which is determined by a preset number of verifications, the entire process of S101 (acquiring cutting duration and force data) and S102 (performing time integration) is repeated to collect a new set of load data samples that reflect the current actual working conditions. Theoretically, if the sudden drop in load is due to the replacement of the low-resistance material, then in the following cuts, as long as the material remains unchanged, the calculated single load index should continue to remain at a new, lower level. Conversely, if the previous sudden drop was just an accidental measurement error or abnormal fluctuation, then in these cuts, the load index is likely to rebound to near the previous average level.

[0058] S107. If the real-time single-verification cut load index is lower than the load sliding average value before the verification counter is started, increment the count value of the verification counter by one.

[0059] Among them, the real-time single-validation cut load index refers to the single load index generated by each cut within the validation window period of S106; the load sliding average before starting the validation counter specifically refers to the historical average calculated from the load index queue at that time before the validation process was triggered in S105, representing the old steady-state load level before the state change occurred; incrementing the validation counter value by one means performing an auto-increment operation on the counter variable initialized in S105.

[0060] Specifically, the core objective of this step is to verify the stability of the load drop. For each cut in the preset number of verification cycles, once the real-time single-verification cut load index is calculated via S102, a conditional judgment is immediately executed. This new load index is compared with the load moving average recorded when verification was triggered in S105. If the new load index is less than the old moving average, the validity of this condition logically provides supporting evidence for the hypothesis that a new, low-load steady state has been entered. Therefore, the counter is incremented, recording this successful verification. If the new load index is equal to or greater than the old moving average, it indicates that a load rebound has occurred, failing to meet the assumption of sustained low load, and the counter will not perform any operation. This step is repeated until the verification cycle in S106 ends, and the final value of the verification counter quantifies the consistency of the sustained low load phenomenon.

[0061] S108. After completing the cutting operation with the preset number of verifications, if the final count value of the verification counter is equal to the preset number of verifications and the average load index of verification is equal to or less than the preset physical reference value of the cutter, then the cumulative load index is set to zero.

[0062] The timing of this step is defined as follows: after completing the preset number of cutting operations, the verification cycle in S106 is completely finished. The final count value of the verification counter refers to the value at which the verification counter finally stops after repeated judgments and accumulations in S107. "Equal to the preset number of verifications" is a logical condition requiring the final value of the counter to be exactly equal to the size of the verification window, indicating that each verification cut meets the low-load condition. Setting the cumulative load index to zero means modifying the core variable recording the total wear of the cutter in S103 to 0. The verification average load index is the arithmetic mean of the load indices of a single cut during the preset number of cutting operations. The preset physical reference value of the cutter is a key parameter calibrated experimentally. For example, during the factory calibration stage, multiple new cutters of the same model can be used to cut standard test materials (such as coated paper of a specific weight) multiple times, and the load index of each single cut can be collected and statistically averaged to obtain a statistically significant reference value. Alternatively, after the user installs the new blade for the first time and confirms it through the system interface, the printer can automatically execute an initial learning program to record the load index of the first few cuts as the physical reference for the new blade.

[0063] Specifically, once the preset number of verification cuts in S106 is completed, the final decision-making stage begins, which includes two layers of decision trees.

[0064] First-level decision: Determine stability. Read the final value of the verification counter. If this value is less than the preset number of verifications, it indicates that a load rebound occurred during the verification period, and the load drop is not a stable event. This could be a measurement error or an accidental cutting anomaly. In this case, the assumption is deemed invalid, and the historical snapshot recovery process in S105 is directly executed to restore the cumulative load index and other states to the state before the drop occurred, thereby avoiding incorrect judgment, and the process ends.

[0065] Second-level decision-making: Differentiate the root cause of the event (material change and cutter change). Calculate the verification average load index for these verification cuts. Then, compare the verification average load index with the preset physical baseline value for the cutter.

[0066] Scenario 1: Material Replacement Determined. If the verified average load index, although lower than the old moving average, is still higher than the cutter's physical baseline value, this is most likely a material replacement (e.g., from thick PET to thin coated paper). The wear condition of the cutter itself has not changed. Therefore, the current cumulative load index is retained, as the wear history of the old cutter remains valid. This verified new steady-state load level is used to reset or quickly update the load index queue of S104, thereby establishing a completely new and accurate dynamic load baseline for the new material.

[0067] Scenario 2: Blade Replacement Determined. If the verified average load index is close to or lower than the preset physical baseline value for the blade, it is determined that this is a physical blade replacement operation, and the user has installed a brand new blade. Therefore, the cumulative load index is set to zero. Because the old blade has been replaced, the wear record is naturally invalidated and cleared, allowing the new blade's lifecycle record to start from the beginning.

[0068] In some embodiments, to address situations where the verification process rebounds or becomes unstable after a sudden load drop, a state rollback mechanism based on historical snapshots can be implemented to reverse misjudgments of the unstable event, thereby ensuring the accuracy of the cumulative load index.

[0069] The trigger condition for this process is that after the verification cycle in S106 ends, the final count value read is less than the preset number of verifications. The physical meaning of this inequality is that in the preset number of verification cuts, at least one or more single-cut load indices exceed the newly formed low-load judgment threshold after the sudden drop. This phenomenon is called load bounce, directly indicating that the initially detected load drop is not a stable, persistent event. Without this mechanism, incorrect subsequent judgments might be made based on this transient and unreliable pseudo-drop data, such as incorrectly updating the baseline load or, more seriously, resetting the wear record to zero, leading to the catastrophic failure of the entire wear assessment model.

[0070] First, the system accesses a historical snapshot that was pre-stored in a temporary storage area (such as RAM or cache) before entering the verification process (i.e., in step S105). This snapshot is a complete backup of all critical state parameters (the core being the cumulative load index, which may also include load queues, etc.) at the moment the system decides to enter the verification process; it is essentially a restore point. Next, the system reads the cumulative load index value from the snapshot and uses this historical true value to forcibly overwrite any cumulative load index values ​​in memory that may have been affected by erroneous expectations.

[0071] The above technical steps, by forcibly restoring the system state to a historical snapshot before the event when verification fails, can actively ignore and isolate the unstable and occasional load fluctuation data, thereby avoiding the cumulative load index from being contaminated by erroneous data or being incorrectly cleared to zero, and ultimately ensuring the long-term reliability and data purity of the cutter wear assessment model.

[0072] In other embodiments, after initially determining that the load drop is a stable event (whether it is a material change or a cutter change), a slow-release monitoring process can be further introduced to achieve the technical effect of continuously and dynamically confirming the new load status and preventing misjudgment caused by delayed load rebound.

[0073] First, after the decision in S108 is completed, meaning the system has accepted the new load state (whether the cumulative index is retained or zeroed out), a buffer monitoring period begins. This period includes a preset number of consecutive cut operations (e.g., 100). During this period, continuous, real-time state tracking is performed: for each cut, the real-time buffered single-cut load index is acquired, and the load index queue in S104 is dynamically updated with this new data, while the latest load moving average is calculated. Essentially, this process involves testing this new low-load state and continuously updating the baseline understanding of this new state.

[0074] The core of this process lies in performing a logical judgment during each cut in the slow-release monitoring: comparing the current real-time slow-release single-cut load index with a historical baseline value. This historical baseline value is the moving average of the load before the verification counter was activated (i.e., before S105), representing the old high-load state. When the real-time load index exceeds a preset rebound percentage (e.g., 50% or 60%) of this old high-load average, a severe delayed load rebound is determined to have occurred. This rebound may stem from certain special reasons, such as an anomaly in a section of the new material, or a hidden defect in the newly replaced cutter, causing a sharp increase in load after a short period of use. Once such a rebound is detected, the original cumulative load index is read from the historical snapshot stored in S105 and overwritten with the current value.

[0075] This operation undoes all judgments and state changes since the load slump was identified, ensuring the system returns to its original, most reliable state and avoiding the accumulation of errors based on a slump event that ultimately proves to be a hoax.

[0076] The above technical steps establish a dual verification mechanism to deal with non-real-time state changes. By adding a continuous monitoring easing period after the initial verification, it is possible to capture in real time those delayed load rebounds that were not exposed in the short-term verification and to trigger a complete state rollback in an instant. This reduces the risk of final misjudgment caused by nonlinear changes in the state of materials or equipment and provides a guarantee for the long-term accuracy of wear assessment.

[0077] S109. When the cumulative load index reaches the preset wear warning threshold, issue a cutter maintenance warning message.

[0078] Among them, the cumulative load index is the updated core variable representing the total wear of the cutter; the preset wear warning threshold is a specific upper limit of cumulative load that is pre-calibrated based on the cutter's designed service life, the average wear coefficient of the material, and a large amount of destructive experimental data. In a physical sense, it represents the critical point at which the cutter goes from a brand-new state to when its cutting performance (such as the smoothness of the cutting edge and the condition of burrs) begins to decline unacceptably; the cutter maintenance warning information refers to a clear notification or operation suggestion issued to the operator through the printer's own user interface (such as the LCD display, flashing or color-changing LED indicator) or through the connected host computer software interface (such as the driver pop-up), indicating that the cutter's lifespan is about to end or has already been exhausted.

[0079] Specifically, the current value of the updated cumulative load index is compared with a preset wear warning threshold stored in the firmware. If the cumulative load index value reaches or exceeds the preset warning threshold for the first time, the comparison result is "yes," immediately triggering a preset warning event handling function. This function, based on a preset warning method, controls the corresponding hardware interface or software API to issue a clear maintenance signal, such as displaying a message on the screen stating that the cutter's lifespan has ended and requesting immediate replacement, possibly accompanied by a buzzer sound.

[0080] In the above embodiments, a multi-level verification mechanism is triggered by dynamically capturing the load drop rate through a load sliding average. By activating a verification counter, the stability of the new working state is confirmed by continuously verifying whether the load remains stable at a low level during subsequent cuts. After confirming stability, the verification average load index of this new state is compared with a preset physical reference value representing a brand-new cutter. Therefore, even if a sudden drop in load occurs due to material replacement, the cumulative index will not be incorrectly reset as long as the stabilized load value fails to reach the new cutter reference value. This distinguishes between material replacement and actual cutter maintenance, solving the problem of maintenance management failure caused by the inability to distinguish event types in existing technologies.

[0081] In other embodiments of this application, when frequently changing materials with vastly different physical properties, misjudgment may occur due to the accidental similarity between the cutting fingerprint of a new material and the fingerprint of a new cutting tool. The label printer cutting control method provided in this application can prioritize excluding cases where the fingerprint matches a known material library before determining whether it is a new cutting tool, thereby improving the accuracy of decision-making under complex working conditions.

[0082] like Figure 2 The diagram shown is another flowchart illustrating the label printer cutting control method provided in this application, which includes the following steps: S201. Acquire cutting duration and cutting force data during real-time cutting operation.

[0083] S202. Integrate the cutting force data acquired during the cutting time over time to obtain the real-time single-cut load index.

[0084] S203. Add the real-time single-cut load index to the currently stored cumulative load index to obtain the real-time cumulative load index.

[0085] S204. Update the load index queue of the historical single-cut load index with a preset number of storage times, enqueue the real-time single-cut load index from the tail of the queue and dequeue the single-cut load index ranked at the head of the queue.

[0086] Steps S201-S204 and Figure 1 Steps S101-S104 in the illustrated embodiment are similar and can be found in the descriptions of steps S106-S109, which will not be repeated here.

[0087] S205. When the load descent rate first reaches the reset descent rate threshold, retrieve the continuous load data collected in the most recent cutting action that covers the entire cutting process to obtain the most recent instantaneous load shape curve.

[0088] Among them, the load drop rate refers to the percentage decrease of the current single-cut load index relative to the previous stable phase load sliding average, used to quantify the severity of the load reduction; the reset drop rate threshold is a preset load drop rate threshold used to trigger in-depth analysis, indicating that a critical event is considered to have occurred only when the load drops drastically to a certain extent; the most recent cutting action refers to the physical cutting process that triggered the load drop rate threshold; continuous load data covering the entire cutting process refers to the complete time series load readings from the moment the cutter contacts the workpiece to the moment it leaves the workpiece, recorded by sensors at a high sampling frequency (e.g., hundreds or thousands of times per second); the most recent instantaneous load shape curve is a curve graph formed by visualizing the above continuous load data with time as the X-axis and load value as the Y-axis, which can show the dynamic change process of force in a single cut.

[0089] Specifically, upon detecting the moment when the load drop rate first reaches or exceeds the reset drop rate threshold through calculation in S204, the system switches from routine macroscopic average monitoring to in-depth microscopic analysis of specific events. During equipment operation, not only is the average load index calculated for each cut, but raw, high-frequency data streams from load sensors (such as servo motor current and force sensors) are continuously stored in a temporary circular buffer in the background. This buffer typically stores continuous data from the most recent few seconds. When S205 is triggered, firstly, based on the timestamp of the triggering event, the complete data segment corresponding to the most recent cut action that caused the sudden load drop is located in the circular buffer. Then, this high-fidelity continuous load data is retrieved from the buffer. This data is not a single average value, but a vector containing details of all stages, including the start, rise, peak, fall, and end of the cut. Finally, this data vector is defined as the most recent instantaneous load morphology curve and passed to subsequent steps for morphological analysis. The advantage of this approach is that it preserves the most original and abundant on-site information for subsequent accurate judgment.

[0090] It is understandable that other methods can be used to achieve this step, such as using double buffering technology to achieve seamless data recording and retrieval, etc., which are not limited here.

[0091] S206. When the peak value of the most recent instantaneous load pattern curve is less than the historical baseline value and the difference between the two values ​​is greater than the preset difference threshold, the real-time cutting fingerprint parameters are obtained for the net peak value portion of the most recent instantaneous load pattern curve.

[0092] Among them, the peak value of the curve represents the maximum load value on the instantaneous load profile curve obtained by S205; the historical baseline value refers to the sliding average load during the stable working phase before the load drop, representing the normal load level of the old tool or old material; the preset difference threshold is a load difference threshold used for preliminary validity verification to ensure that the analysis is not a small random fluctuation; the net peak value of the curve refers to the part of the load profile curve that is significantly higher than the baseline noise, that is, the main pulse region from the beginning of the significant load increase to the fall back to the initial level, representing the core process of effective physical interaction between the cutter and the material; the peak height specifically refers to the difference between the maximum value of the net peak value and the starting baseline of that part; the duration specifically refers to the time span from the start point to the end point of the net peak value; the real-time cutting fingerprint parameter is a ratio obtained by dividing the peak height by the duration.

[0093] Specifically, after S205 successfully acquires the load curve, it first performs a pre-check to determine whether the curve is worth analyzing. The pre-check condition is that the peak value of the curve must be significantly lower than the historical baseline value (i.e., the old average load), and the difference between the two must be greater than a preset absolute threshold. This pre-check step can effectively filter out anomalies such as high peak values ​​even though the average load has decreased (e.g., sensor failure), ensuring that subsequent computing resources are only used for meaningful, truly low-load events.

[0094] After pre-detection, the cutting fingerprint is calculated. Net peak extraction: First, the net peak portion must be identified from the complete curve data. This is achieved through an algorithm, for example, starting the search from the beginning of the curve. When the load value exceeds a certain noise threshold, it is marked as the starting point; then the search continues until the load value falls back below that threshold, marked as the ending point. The data segment between the starting and ending points is the net peak portion. Fingerprint parameter calculation: Within the extracted net peak data segment, two key indicators are calculated: peak height, i.e., the maximum value within the data segment; and duration, i.e., the time difference between the ending and starting points. Finally, the peak height is divided by the duration to obtain the real-time cutting fingerprint parameters. The physical meaning of this parameter is that a brand-new, sharp cutter typically generates a high and narrow load pulse (large peak height, short duration) during cutting, thus its fingerprint parameter value is relatively large. Conversely, a load decrease due to material change may not necessarily result in a sharper pulse pattern.

[0095] In some embodiments, the cutting fingerprint parameter calculation in this step can be implemented in a variety of ways to capture different physical characteristics: Optionally, energy fingerprint parameters based on curve integrals: perform the same pre-detection and net peak extraction; calculate the area under the curve of the net peak portion (i.e., time integration of the load value) to obtain the total energy consumed in this cutting as the fingerprint parameter; compare this energy value with the energy value of historical new cuts.

[0096] It is understandable that this step can be achieved in other ways, such as using Fourier transform to analyze the frequency components of the curve as a fingerprint, etc., which are not limited here.

[0097] S207. When the difference between the real-time cutting fingerprint parameters and the historical cutting fingerprint parameters is within the preset cutting fingerprint error threshold range, the cumulative load index is reset to zero.

[0098] Among them, the real-time cutting fingerprint parameter refers to the value calculated by S206 that represents the characteristics of the current cutting event; the historical cutting fingerprint parameter is the cutting fingerprint parameter calculated and stored within the preset initial learning period after the last cumulative load index was reset; the preset cutting fingerprint error threshold is an allowable, small difference range used to determine whether two fingerprint parameters are similar enough to tolerate measurement noise and small differences; the initial learning period refers to an initial working time after confirming a cutter replacement (i.e., the last reset of the cumulative load index), such as the first 10 or 20 cuts, during which the fingerprint benchmark of the new cutter is specifically learned and established.

[0099] Specifically, after S206 successfully calculates the real-time fingerprint parameters, it executes a process to confirm whether a physical cutter replacement has occurred by comparing the fingerprint of the current event with the fingerprint of a known new cutter.

[0100] Once the previous cumulative load index is successfully reset to zero (i.e., a tool change is confirmed), an initial learning cycle begins. During this cycle, analyses S205 and S206 are performed on each cut to obtain a series of fingerprint parameters. After the learning cycle ends, these parameters are statistically processed (e.g., averaged, median, or averaged after removing outliers) to obtain a stable historical cutting fingerprint parameter that is fully specific to the current working conditions (equipment, material, tool type), and this parameter is stored.

[0101] Once the real-time cutting fingerprint parameters for this event are calculated, they are compared with the stored historical cutting fingerprint parameters. If the absolute difference between the two is less than or equal to a preset cutting fingerprint error threshold, a match is determined. This match is considered strong evidence of a cutter replacement event because it means that the current cutting behavior pattern is highly consistent with a known new cutter. Once a match is determined, the final action is performed: the core wear record, the cumulative load index, is reset to zero.

[0102] S208. When the peak value of the most recent instantaneous load pattern curve is less than the historical baseline value and the difference between the curve and the historical baseline value is greater than the preset difference threshold, the cumulative load index is reset to zero.

[0103] The historical baseline value is the load moving average value before the start of the verification counter.

[0104] The core of this step lies in proposing a more direct judgment criterion that runs parallel to the S206-S207 fingerprint analysis path. The load moving average before activating the verification counter further clarifies the source of the historical baseline value, ensuring the accuracy of the comparison benchmark.

[0105] Specifically, the triggering condition is exactly the same as the pre-detection condition of S206: that is, after obtaining the curve in S205, it is found that the peak value of the curve has decreased significantly compared with the historical baseline value (old stable load).

[0106] If the peak load of a single cut has already dropped to a very low level, this phenomenon most likely indicates that the physical cutter has been replaced. The underlying physical assumption is that any change in material or operating technique, while potentially reducing the average load, is unlikely to reduce the peak force at the instant of a single cut; this is only possible with a brand-new, extremely sharp blade.

[0107] Once the condition that the peak value of the curve is much smaller than the historical baseline value is met, the fingerprint calculation and comparison process in S206 and S207 can be bypassed, a judgment that the cutter has been replaced can be made, and the operation of resetting the cumulative load index to zero can be performed. This step can be regarded as an upgraded version of the simple logic in Example 1, because it no longer judges the average value, but the more representative peak value.

[0108] In some embodiments, the direct decision-making logic in this step can be implemented in multiple ways to adapt to different scenarios: Optionally, peak determination based on relative decline rate: calculate the relative decline rate of the curve peak relative to the historical baseline value, i.e. (historical baseline value - curve peak value) / historical baseline value; when the relative decline rate is greater than a very high threshold, perform a reset.

[0109] Optionally, a dual judgment of peak value and area can be combined: simultaneously checking whether the peak value of the curve is less than the peak value threshold and whether the integral area under the curve is less than the area threshold; only when both conditions are met is the reset operation performed. This method, by adding a judgment dimension, can further eliminate false low peak values ​​caused by momentary sensor failure, thus improving reliability.

[0110] It is understandable that this step can be achieved in other ways, such as determining whether the duration of the peak load is extremely short, etc., which are not limited here.

[0111] like Figure 3 As shown, this is a visualization of steps S205 to S207 in Example 2, demonstrating how further analysis distinguishes two fundamentally different physical events when the system detects a sudden drop in load (i.e., the peak values ​​of curves B and C are much lower than those of curve A).

[0112] Step S205 involves retrieving a complete instantaneous load pattern curve, similar to curve B or curve C in the figure, from the high-frequency data cache after the system detects a significant drop in the average load. Step S206 performs a mathematical analysis of this retrieved curve, calculating the peak height and net peak duration marked in the figure using an algorithm, and defining the ratio of these two as the cutting fingerprint parameter. Finally, step S207 performs the final decision judgment, the logic of which is most intuitively illustrated in the figure: if the calculated fingerprint parameter is large (corresponding to the tall and thin shape of curve B), it is determined to be a genuine cutter replacement, and the wear record is reset; conversely, if the fingerprint parameter is small (corresponding to the short and wide shape of curve C), it is determined to be merely a material replacement, and the wear record remains unchanged. In this way, the figure powerfully demonstrates how the present invention solves the common misjudgment problem in the prior art by analyzing two-dimensional curve morphological characteristics, rather than one-dimensional average values.

[0113] S209. When the load decline rate is greater than the preset reset decline rate threshold, the current cumulative load index is stored as a historical snapshot in the temporary storage area, and a verification counter with an initial value of zero is started.

[0114] Step S209 and Figure 1 Step S105 in the illustrated embodiment is similar and can be found in the descriptions of steps S106-S109, which will not be repeated here.

[0115] In some embodiments, before calculating the load drop rate, a dynamic compensation mechanism based on the real-time operating voltage of the cutter motor can be introduced to correct the interference caused by grid voltage fluctuations on the load index, thereby improving the signal-to-noise ratio from the data source.

[0116] Specifically, this step aims to address the interference of grid voltage fluctuations on load measurement. The theoretical basis is that the output torque and electrical parameters (such as operating current) of the cutter motor are closely related to the input voltage. Under constant load conditions, a decrease in grid voltage typically causes the motor to draw in more current to maintain output torque, and vice versa. Since the load index in this application is usually directly related to electrical parameters such as motor current or power, fluctuations in grid voltage will directly translate into fluctuations in the load index, potentially triggering an incorrect judgment of a load slump or masking a genuine slump event.

[0117] While acquiring the real-time single-cut load index for each cut, the real-time operating voltage of the cutter motor is also synchronously acquired via a voltage sensor. A preset standard reference voltage is stored, which is typically the factory's rated power supply voltage (e.g., three-phase 380V or single-phase 220V). The real-time voltage is compared with this standard voltage, and the percentage deviation of the current voltage is calculated using the formula: Voltage Deviation Rate = (Real-time Voltage - Standard Voltage) / Standard Voltage. This deviation rate is a signed value, negative for excessively low voltage and positive for excessively high voltage. Based on the calculated voltage deviation rate, the original load index is compensated in reverse.

[0118] When the real-time voltage is lower than the standard voltage (negative deviation rate), it means that the original load index may be inflated due to the motor drawing a larger current. In this case, the load index is adjusted downwards proportionally to the voltage deviation rate. For example, if the voltage is 5% lower (deviation rate -0.05), then the corrected index = original index * (1 - 0.05) = original index * 0.95.

[0119] When the real-time voltage is higher than the standard voltage (positive deviation rate), it means that the original load index may be lowered due to the motor drawing less current. In this case, the load index is adjusted upwards proportionally to the voltage deviation rate. For example, if the voltage is 3% higher (deviation rate +0.03), then the corrected index = original index * (1 + 0.03) = original index * 1.03.

[0120] The corrected real-time single-cut load index obtained after the above compensation calculation will replace the original, uncorrected load index and be used in all subsequent calculation processes, including updating the load index queue (S204) and calculating the load drop rate that ultimately triggers S209.

[0121] The above technical steps monitor grid voltage fluctuations in real time and use this as a basis to perform reverse compensation on load measurements related to voltage changes. This can eliminate electrical noise introduced by unstable power supply and ensure that the load decline rate used for final decision-making only reflects the actual physical wear or material changes. This reduces the system misjudgment rate caused by grid interference and greatly improves the robustness and reliability of decision-making.

[0122] S210. In the cutting operation with a preset number of verifications after the verification counter is started, obtain the real-time single verification cutting load index corresponding to each cutting.

[0123] S211. If the real-time single-verification cut load index is lower than the load sliding average value before the verification counter is started, increment the count value of the verification counter by one.

[0124] S212. After completing the cutting operation with a preset number of verifications, if the final count value of the verification counter is equal to the preset number of verifications and the average load index of verification is equal to or less than the preset physical reference value of the cutter, then the cumulative load index is set to zero.

[0125] S213. When the cumulative load index reaches the preset wear warning threshold, issue a cutter maintenance warning message.

[0126] Steps S210-S213 and Figure 1 Steps S106-S109 in the illustrated embodiment are similar and can be found in the descriptions of steps S106-S109, which will not be repeated here.

[0127] In the above embodiments, when a sudden drop in load is detected, the system no longer relies solely on a single average load value. Instead, it retrieves and analyzes instantaneous load profile curves covering the entire cutting process, thereby obtaining higher-dimensional data information. Furthermore, by calculating the ratio of the peak height to the duration of the curve, a cutting fingerprint parameter characterizing the sharpness of the cutting process is constructed. This parameter can distinguish between two physically distinct situations: cutting with a new blade under low load (high peak height-to-duration ratio) and cutting soft materials with an old blade. By making judgments based on insight into process details, the accuracy of blade replacement event identification is improved.

[0128] The following describes an exemplary label printer cutting control system 400 provided in an embodiment of this application. Figure 4 This is an exemplary hardware structure diagram of the label printer cutting control system 400 provided in this application embodiment.

[0129] In some embodiments, the label printer cutting control system 400 is a computer device or includes a computer device. The computer device includes a processor, memory, and a network interface connected via a system bus. The processor of the computer device provides computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores an operating system, computer programs, and a database. The internal memory provides an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The database of the computer device stores data. The network interface of the computer device is used to communicate with other external terminals or servers via a network connection. In some embodiments, the network interface can be a wired network interface; in some embodiments, the network interface can also be a wireless network interface. When the computer program is executed by the processor, it implements the methods in the embodiments of this application.

[0130] Those skilled in the art will understand that Figure 4The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the computer device to which the present application is applied. Specific computer devices may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0131] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit it. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

[0132] As used in the above embodiments, depending on the context, the term "when..." can be interpreted as "if...", "after...", "in response to determining...", or "in response to detecting...". Similarly, depending on the context, the phrase "when determining..." or "if (the stated condition or event) is interpreted as "if determining...", "in response to determining...", "when (the stated condition or event) is detected", or "in response to detecting (the stated condition or event)".

[0133] In the above embodiments, implementation can be achieved entirely or partially through software, hardware, firmware, or any combination thereof. When implemented using software, it can be implemented entirely or partially in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer program instructions are loaded and executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., coaxial cable, fiber optic, digital subscriber line) or wireless (e.g., infrared, wireless, microwave, etc.) means. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that integrates one or more available media. The available medium can be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium (e.g., solid-state drive), etc.

[0134] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. This program can be stored in a computer-readable storage medium, and when executed, it can include the processes described in the above method embodiments. The aforementioned storage medium includes various media capable of storing program code, such as ROM or random access memory (RAM), magnetic disks, or optical disks.

Claims

1. A label printer cutting control method, characterized in that, include: Acquire cutting duration and cutting force data during real-time cutting operations; The cutting force data acquired within the cutting time is integrated over time to obtain the real-time single-cut load index; The real-time single-cut load index is added to the currently stored cumulative load index to obtain the real-time cumulative load index; Update the load index queue that stores the historical single-cut load index of a preset number of times, and enqueue the real-time single-cut load index from the tail of the queue and dequeue the single-cut load index ranked at the head of the queue. When the load drop rate exceeds the preset reset drop rate threshold, the current cumulative load index is stored as a historical snapshot in the temporary storage area, and a verification counter with an initial value of zero is started. The load decrease rate is the ratio of the difference between the load sliding average and the real-time single-cut load index to the load sliding average; the load sliding average is the arithmetic mean of all single-cut load indices in the load index queue. In the cutting operation with a preset number of verifications after the verification counter is started, the real-time single verification cutting load index corresponding to each cutting is obtained; If the real-time single-verification cut load index is lower than the load sliding average value before the verification counter is started, the count value of the verification counter is incremented by one. After completing the cutting operation for the preset number of verifications, if the final count value of the verification counter is equal to the preset number of verifications and the average verification load index is equal to or less than the preset physical reference value of the cutter, then the cumulative load index is set to zero. The verification average load index is the arithmetic mean of the load index of a single cut in the cutting operation of the preset number of verifications. When the cumulative load index reaches the preset wear warning threshold, a cutter maintenance warning message is issued.

2. The method according to claim 1, characterized in that, After completing the cutting operation for the preset number of verifications, if the final count value of the verification counter is equal to the preset number of verifications and the average verification load index is equal to or less than the preset physical reference value of the cutter, then after setting the cumulative load index to zero, the method further includes: In the continuous cutting operation with a preset number of slow-release cycles, the real-time slow-release single-cut load index is continuously acquired, the load index queue is updated, and the latest load moving average is calculated. When the real-time slow-release single-cut load index exceeds the preset rebound ratio of the load sliding average value before the verification counter is started, the current cumulative load index is set to the value corresponding to the historical snapshot, and the data in the load index queue is restored to the state before the verification counter is started.

3. The method according to claim 1, characterized in that, After updating the load index queue containing historical single-cut load indices stored a preset number of times, and enqueuing the real-time single-cut load index from the tail of the queue and dequeuing the single-cut load index ranked at the head of the queue, the process further includes: When the load decline rate first reaches the reset decline rate threshold, the continuous load data collected in the most recent cutting action, covering the entire cutting process, is retrieved to obtain the most recent instantaneous load shape curve; When the peak value of the most recent instantaneous load pattern curve is less than the historical baseline value and the difference between the curve and the historical baseline value is greater than a preset difference threshold, the cumulative load index is reset to zero; the historical baseline value is the load sliding average value before the verification counter is started.

4. The method according to claim 3, characterized in that, When the load descent rate first reaches the reset descent rate threshold, after retrieving continuous load data covering the entire cutting process collected in the most recent cutting action to obtain the most recent instantaneous load profile curve, the process further includes: When the peak value of the most recent instantaneous load pattern curve is less than the historical baseline value and the difference between the peak value and the historical baseline value is greater than a preset difference threshold, a real-time cutting fingerprint parameter is obtained for the net peak value portion of the most recent instantaneous load pattern curve; the cutting fingerprint parameter is obtained by calculating the ratio of the peak height of the net peak value portion of the curve to the duration of the net peak value portion of the curve. When the difference between the real-time cutting fingerprint parameters and the historical cutting fingerprint parameters is within the preset cutting fingerprint error threshold range, the cumulative load index is reset to zero; the historical cutting fingerprint parameters are the cutting fingerprint parameters calculated and stored within the preset initial learning period after the last cumulative load index was reset.

5. The method according to claim 1, characterized in that, After completing the cutting operation for the preset number of verifications, if the final count value of the verification counter is equal to the preset number of verifications and the average verification load index is equal to or less than the preset physical reference value of the cutter, then after setting the cumulative load index to zero, the method further includes: If the final count value is less than the preset number of verifications, the historical snapshot is read from the temporary storage area, and the cumulative load index is set to the value corresponding to the historical snapshot.

6. The method according to claim 1, characterized in that, Before storing the current cumulative load index as a historical snapshot in the temporary storage area and starting a verification counter with an initial value of zero when the load decline rate exceeds a preset reset decline rate threshold, the method further includes: After each cutting operation, the time interval between the end of the current cutting and the arrival of the next cutting command is recorded and recorded as the instantaneous cutting interval. The average working rhythm parameters are obtained by calculating the sliding average of the instantaneous cutting intervals of the most recent preset rhythm threshold in real time. By combining the preset rhythm-load compensation curve, the average working rhythm is mapped to a thermal effect compensation factor; The thermal effect compensation factor is added to the real-time single-cut load index to correct the real-time single-cut load index, and then used to replace the real-time single-cut load index in calculating the load drop rate.

7. The method according to claim 1, characterized in that, Before storing the current cumulative load index as a historical snapshot in the temporary storage area and starting a verification counter with an initial value of zero when the load decline rate exceeds a preset reset decline rate threshold, the method further includes: The real-time operating voltage of the cutter motor is obtained, and the voltage deviation rate between the real-time operating voltage of the cutter motor and the preset standard reference voltage is calculated; the voltage deviation rate is the ratio of the difference between the real-time operating voltage of the cutter motor and the preset standard reference voltage to the preset standard reference voltage. When the real-time cutter motor operating voltage is lower than the preset standard reference voltage, the load index is lowered according to the voltage deviation rate. When the real-time cutter motor operating voltage is higher than the preset standard reference voltage, the load index is raised according to the voltage deviation rate. The corrected real-time single-cut load index is obtained and used to replace the real-time single-cut load index to calculate the load drop rate.

8. A label printer cutting control system, characterized in that, The label printer cutting control system includes: one or more processors and a memory; the memory is coupled to the one or more processors, the memory is used to store computer program code, the computer program code including computer instructions, and the one or more processors call the computer instructions to cause the label printer cutting control system to perform the method as described in any one of claims 1-7.

9. A computer program product containing instructions, characterized in that, When the computer program product is run on the label printer cutting control system, the label printer cutting control system performs the method as described in any one of claims 1-7.

10. A computer-readable storage medium comprising instructions, characterized in that, When the instruction is executed on the label printer cutting control system, the label printer cutting control system performs the method as described in any one of claims 1-7.

Images