Liquid level detection method for anti-reflection glue material mixing and metering tank

Abstract

The present application relates to the technical field of liquid level detection, and particularly relates to a liquid level detection method for anti-reflection glue raw material mixing and a metering tank. The present application obtains the actual density of the simulated adhesion layer of the tank wall after mixing, the initial basic density of the anti-reflection glue raw material, the real-time adhesion layer thickness of the tank wall, the apparent liquid level and the shape characteristics of the metering tank, and obtains the effective volume liquid level of the anti-reflection glue raw material mixing. In combination with the dielectric constant of the raw material mixed liquid, the dielectric constant and the density of the pure polar component and the pure non-polar component, the mass equivalent liquid level of the anti-reflection glue raw material mixing is obtained. The liquid surface image of each frame during mixing, the stirring vibration power and the flow change frequency are obtained in real time, in combination with the dielectric constant of the raw material mixed liquid and the gray scale distribution characteristics on each frame of the liquid surface image, the liquid level abnormality judgment factor is obtained, and the real liquid level is obtained. The present application accurately distinguishes the true and false liquid levels by analyzing the liquid level abnormality judgment factor, and then corrects the liquid level measurement error in real time, thereby improving the accuracy of the liquid level detection.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of liquid level detection, and in particular to a liquid level detection method for anti-reflective glue raw material mixing and a metering tank. BACKGROUND

[0002] In the production process of anti-reflective glue in the field of optical film and display screen, the raw material mixing precision directly affects the coating light transmittance and uniformity, and uneven mixing may cause problems such as coating porosity, insufficient adhesion, and impurity residue, and the liquid level detection is a key link for controlling the proportioning.

[0003] In the prior art, liquid level detection is performed through multi-sensor redundancy or algorithm filtering compensation, but the anti-reflective glue raw material mixing often involves high-viscosity and strongly corrosive liquid, and the liquid turbulence and bubble generation in the dynamic mixing process further aggravate the liquid level fluctuation, the existing detection method is difficult to distinguish between the real liquid level and the false liquid level, resulting in deviation of the raw material addition amount, and the real-time performance and anti-interference of the liquid level detection under high-viscosity and multiphase flow conditions have not been fundamentally solved, and the liquid level detection effect is poor. SUMMARY

[0004] In order to solve the technical problem of poor liquid level detection effect under high-viscosity and multiphase flow conditions in the prior art, the purpose of the present application is to provide a liquid level detection method for anti-reflective glue raw material mixing and a metering tank, and the technical solution adopted is as follows:

[0005] The present application provides a liquid level detection method for anti-reflective glue raw material mixing, which comprises the following steps:

[0006] Simulating anti-reflective glue raw material mixing in the metering tank, obtaining the apparent liquid level according to the initial basic density, pressure data and gravitational acceleration of the anti-reflective glue raw material;

[0007] According to the variation characteristics of the measured shear stress under different preset stirring powers, the latest shear stress under the real-time stirring power is obtained, and according to the thickness growth value of the tank wall adhesion layer per unit time under different preset shear stresses, the real-time adhesion layer thickness of the tank wall under the latest shear stress is obtained;

[0008] The actual density of the tank wall adhesion layer after simulation mixing is obtained, and the effective volume liquid level of the anti-reflective glue raw material mixing is obtained by combining the initial basic density of the anti-reflective glue raw material, the real-time adhesion layer thickness of the tank wall, the apparent liquid level and the shape characteristics of the metering tank; and the mass equivalent liquid level of the anti-reflective glue raw material mixing is obtained according to the dielectric constant of the raw material mixed liquid, the dielectric constant and density of the pure polar component and the pure non-polar component, and the effective volume liquid level;

[0009] Real-time acquisition of each frame of liquid surface image during mixing, stirring vibration power and flow rate change frequency, combined with the dielectric constant of the raw material mixed liquid and the gray scale distribution characteristics on each frame of liquid surface image, to obtain the liquid level abnormality judgment factor; according to the liquid level abnormality judgment factor and the quality equivalent liquid level, the real liquid level is obtained.

[0010] Further, the apparent liquid level acquisition method comprises:

[0011] Obtain the product of the initial basic density of the anti-reflection glue raw material and the acceleration of gravity, obtain the ratio between the pressure data and the product result as the apparent liquid level.

[0012] Further, the latest shear stress acquisition method comprises:

[0013] Under different preset stirring powers, obtain the product of the tank cross-sectional area and the measured shear stress, calculate the average value of the ratio of the product result to the corresponding preset stirring power as the standard conversion coefficient of stirring power converted into shear stress;

[0014] Calculate the product of the real-time stirring power and the standard conversion coefficient, calculate the ratio of the product result to the tank cross-sectional area as the corresponding latest shear stress.

[0015] Further, the tank wall real-time adhesion layer thickness acquisition method comprises:

[0016] Obtain the average value of the product of different preset shear stresses and the thickness growth value of the tank wall adhesion layer per unit time, as the theoretical accumulation constant of the adhesion layer;

[0017] Obtain the product of the latest shear stress and the theoretical accumulation constant of the adhesion layer as the latest thickness growth value of the tank wall adhesion layer per unit time under the latest shear stress;

[0018] Integrate the latest thickness growth value of the tank wall adhesion layer per unit time under the latest shear stress in real time, and take the integral result as the tank wall real-time adhesion layer thickness.

[0019] Further, the effective volume liquid level acquisition method comprises:

[0020] Obtain the actual density ratio of the tank wall adhesion layer to the initial basic density of the anti-reflection glue raw material as the density ratio;

[0021] The adhesion layer is equivalent to an annular column, the product of the tank wall circumference, the tank wall real-time adhesion layer thickness and the apparent liquid level is obtained as the adhesion layer volume, and the adhesion layer volume is divided by the density ratio as the adhesion layer corrected volume;

[0022] The ratio of the corrected volume of the adhesion layer to the cross-sectional area of ​​the tank is obtained as the equivalent deviation level of the adhesion layer; the difference between the apparent level and the equivalent deviation level of the adhesion layer is obtained as the effective volume level.

[0023] Furthermore, the method for obtaining the mass equivalent liquid level includes:

[0024] Obtain the first difference in dielectric constant between the raw material mixture and the pure nonpolar component, obtain the second difference in dielectric constant between the pure nonpolar component and the pure polar component, and calculate the ratio of the first difference and the second difference as the proportion of the pure polar component.

[0025] Obtain the product of the proportion of pure polar components and their corresponding densities, and use it as the density contribution value of the polar components; calculate the difference between the positive integer 1 and the proportion of pure polar components, and calculate the product of the difference result and the density of pure nonpolar components, and use it as the density contribution value of the nonpolar components.

[0026] The sum of the density contribution values ​​of polar and non-polar components is obtained as the real-time mixing density; the ratio of the real-time mixing density to the preset mixing standard density is obtained, and the product of the ratio result and the effective volume liquid level is calculated as the mass equivalent liquid level of the antireflective adhesive raw material mixing.

[0027] Furthermore, the method for obtaining the liquid level anomaly judgment factor includes:

[0028] Based on the dielectric constant of the raw material mixture, the stirring vibration power, and the flow rate change frequency during real-time mixing, the liquid level correlation factor and fluctuation anomaly are obtained;

[0029] Based on the gray-level distribution features on each frame of liquid surface image, multiple bubble regions and gray-level co-occurrence matrix contrast on each frame of liquid surface image are obtained; the fluctuation features of gray-level co-occurrence matrix contrast in different frames of liquid surface image in real time local range are obtained, as well as the product between the mean number of bubble regions, and normalized mapping is performed as the degree of liquid surface fluctuation.

[0030] The product of the liquid level correlation factor, fluctuation anomaly, and liquid surface fluctuation degree is obtained as the liquid level anomaly judgment factor.

[0031] Furthermore, the method for obtaining the liquid level correlation factor and fluctuation anomaly includes:

[0032] The ratio of the flow rate change frequency to the stirring vibration frequency is obtained as the liquid level correlation factor; the ratio of the fluctuation degree of the dielectric constant to the mean dielectric constant in the real-time neighborhood is obtained as the dielectric constant fluctuation rate.

[0033] The ratio of dielectric constant volatility to a preset volatility reference value is obtained and normalized to represent volatility anomalies.

[0034] Furthermore, the method for obtaining the actual liquid level includes:

[0035] If the liquid level anomaly judgment factor is greater than the preset judgment threshold, the corresponding mass equivalent liquid level value will be filtered and used as the true liquid level.

[0036] Conversely, the corresponding mass equivalent liquid level value is used as the true liquid level.

[0037] This invention also proposes a metering tank, including a metering tank body, a controller, and a pressure sensor, a high-frequency dielectric sensor, a piezoelectric vibration sensor, a pulse sensor, and a high-speed industrial camera connected to the controller. The pressure sensor acquires pressure data of the anti-reflective adhesive raw material, the high-frequency dielectric sensor acquires the dielectric constant of the raw material mixture, the piezoelectric vibration sensor acquires the stirring vibration frequency, the pulse sensor acquires the flow rate change frequency, and the high-speed industrial camera acquires each frame of liquid surface image during mixing. The control method of the controller includes:

[0038] The mixing of antireflective adhesive raw materials was simulated in a metering tank. The apparent liquid level was obtained based on the initial base density, pressure data, and gravitational acceleration of the antireflective adhesive raw materials.

[0039] Based on the variation characteristics of measured shear stress under different preset stirring power, the latest shear stress under real-time stirring power is obtained; based on the thickness growth value of the tank wall adhesion layer per unit time under different preset shear stress, the real-time adhesion layer thickness of the tank wall under the latest shear stress is obtained.

[0040] The actual density of the tank wall adhesion layer after simulated mixing is obtained. Combined with the initial base density of the antireflective adhesive raw material, the real-time thickness of the tank wall adhesion layer, the apparent liquid level, and the morphological characteristics of the metering tank, the effective volume liquid level of the antireflective adhesive raw material mixture is obtained. Based on the obtained dielectric constant of the raw material mixture, the dielectric constant and density of the pure polar component and the pure non-polar component, and the effective volume liquid level, the mass equivalent liquid level of the antireflective adhesive raw material mixture is obtained.

[0041] Real-time acquisition of liquid surface images, stirring vibration power, and flow rate change frequency for each frame during mixing; combined with the dielectric constant of the raw material mixture and the grayscale distribution characteristics on each frame of liquid surface images, to obtain a liquid level anomaly judgment factor; based on the liquid level anomaly judgment factor and the mass equivalent liquid level, to obtain the true liquid level.

[0042] The present invention has the following beneficial effects:

[0043] This invention obtains the latest shear stress under real-time stirring power by measuring the variation characteristics of shear stress under different preset stirring power, thus achieving indirect, online, and quantitative assessment of the fluid dynamics environment of the tank wall. Based on the thickness increase of the adhesion layer on the tank wall per unit time under different preset shear stresses, it obtains the real-time adhesion layer thickness under the latest shear stress, achieving theoretical prediction and quantification of the thickness of non-flowable adhesion layers. Furthermore, by obtaining the actual density of the adhesion layer on the tank wall after simulated mixing, the initial base density of the antireflective adhesive raw material, the real-time adhesion layer thickness on the tank wall, the apparent liquid level, and the morphological characteristics of the metering tank, it obtains the effective volume of antireflective adhesive raw material mixture. This invention achieves precise compensation for adhesion errors, obtaining a liquid level that reflects the true volume of flowable raw materials within the tank. By combining the acquired dielectric constant of the raw material mixture, the dielectric constants and densities of the pure polar and pure non-polar components, the equivalent liquid level of the antireflective adhesive raw material mixture is obtained, eliminating the proportioning error caused by density fluctuations due to component changes. Real-time acquisition of each frame of liquid surface image, stirring vibration power, and flow rate change frequency during mixing, combined with the dielectric constant of the raw material mixture and the grayscale distribution characteristics on each frame of the liquid surface image, yields a liquid level anomaly judgment factor, effectively distinguishing between true mass changes and false fluctuations caused by turbulence / bubbles; thus obtaining the true liquid level. This invention accurately identifies true and false liquid levels by analyzing the liquid level anomaly judgment factor, thereby correcting liquid level measurement errors in real time and improving the accuracy of liquid level detection. Attached Figure Description

[0044] To more clearly illustrate the technical solutions and advantages in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0045] Figure 1 A flowchart illustrating a liquid level detection method for mixing antireflective adhesive raw materials according to an embodiment of the present invention;

[0046] Figure 2 This is a flowchart illustrating a method for obtaining liquid level anomaly judgment factors according to an embodiment of the present invention. Detailed Implementation

[0047] To further illustrate the technical means and effects adopted by the present invention to achieve its intended purpose, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of a liquid level detection method and metering tank for mixing antireflective adhesive raw materials according to the present invention. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0048] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0049] The following detailed description, in conjunction with the accompanying drawings, illustrates a specific scheme for a liquid level detection method and metering tank used in the mixing of antireflective adhesive raw materials provided by this invention.

[0050] Please see Figure 1 The diagram illustrates a method flowchart for liquid level detection in the mixing of antireflective adhesive raw materials according to an embodiment of the present invention, specifically including:

[0051] Step S1: Simulate the mixing of antireflective adhesive raw materials in a metering tank, and obtain the apparent liquid level based on the initial basic density, pressure data and gravitational acceleration of the antireflective adhesive raw materials.

[0052] In the embodiments of the present invention, the coating mixing process directly affects the coating quality. Uneven mixing may lead to problems such as coating porosity, insufficient adhesion, and residual impurities. Therefore, it is necessary to strictly monitor and intervene in the raw material mixing process in a timely manner.

[0053] Traditional metering tanks mostly use float-type, ultrasonic, or capacitive level sensors. However, when mixing antireflective adhesive raw materials often involves high-viscosity and highly corrosive liquids, float-type sensors are prone to jamming or drifting errors due to liquid adhesion. Ultrasonic sensors are prone to signal attenuation due to temperature gradients and steam interference inside the tank, while capacitive sensors are not stable enough because their dielectric constant is affected by the chemical properties of the raw materials.

[0054] Therefore, bottom pressure measurement provides a more stable reflection of the total static pressure of the liquid inside the tank, offering a direct and reliable liquid level measurement benchmark that is unaffected by optical or surface factors such as tank wall adhesion, liquid surface foam, steam, and temperature gradients. Thus, based on fluid dynamics analysis, the apparent liquid level is obtained according to the initial base density of the antireflective adhesive raw material, pressure data, and gravitational acceleration.

[0055] Preferably, in one embodiment of the present invention, the method for obtaining the apparent liquid level includes:

[0056] The product of the initial base density and gravitational acceleration of the antireflective adhesive raw material is obtained, and the ratio between the pressure data and the product result is used as the apparent liquid level.

[0057] It should be noted that, in the embodiments of the present invention, the initial foundation density and gravitational acceleration are obtained in advance by the implementers based on relevant experiments under standard working conditions, and will not be elaborated here.

[0058] Step S2: Based on the variation characteristics of the measured shear stress under different preset stirring power, obtain the latest shear stress under the real-time stirring power; based on the thickness increase of the tank wall adhesion layer per unit time under different preset shear stress, obtain the real-time adhesion layer thickness of the tank wall under the latest shear stress.

[0059] There is a strong correlation between stirring power and the average shear stress of the fluid inside the tank. The greater the stirring power, the more energy the stirring paddle transfers to the liquid, the higher the degree of fluid turbulence, and the stronger the shearing effect on the tank wall. Based on the variation characteristics of measured shear stress under different preset stirring powers, the latest shear stress under real-time stirring power is obtained.

[0060] Preferably, in one embodiment of the present invention, the method for obtaining the latest shear stress includes:

[0061] Under different preset stirring power, the product of the tank cross-sectional area and the measured shear stress is obtained, and the average ratio of the product result to the corresponding preset stirring power is calculated as the standard conversion coefficient for converting stirring power into shear stress.

[0062] Calculate the product of the real-time stirring power and the standard conversion factor, and then calculate the ratio of the product result to the cross-sectional area of ​​the tank as the corresponding latest shear stress.

[0063] It should be noted that, in the embodiments of the present invention, standard silicone oil of known viscosity is loaded into the tank, and the preset stirring power is pre-set by the implementer for simulated mixing. The shear stress of the tank wall is obtained by a portable shear stress meter. The method for obtaining the cross-sectional area of ​​the tank is to obtain the inner diameter of the upper, middle and lower parts of the tank wall by a laser diameter measuring instrument, take the average value as the inner diameter of the tank, calculate pi and multiply it by the square of half the inner diameter of the tank to obtain the cross-sectional area of ​​the tank.

[0064] The higher the viscosity of the raw material, the stronger the intermolecular cohesive force, and the easier it is to form an adhesion layer on the metering tank wall during mixing. This layer is difficult to flow with the main fluid. Since the adhesion layer accumulation rate is inversely proportional to the shear stress, that is, the stronger the shear stress, the greater the scouring force of the stirring on the tank wall, and the slower the adhesion layer accumulation. Based on the thickness growth value of the adhesion layer on the tank wall per unit time under different preset shear stresses, the thickness growth value of the adhesion layer on the tank wall per unit time under different preset shear stresses is obtained, and the real-time adhesion layer thickness of the tank wall under the latest shear stress is obtained.

[0065] Preferably, in one embodiment of the present invention, the method for obtaining the real-time adhesion layer thickness on the tank wall includes:

[0066] The average value of the product between different preset shear stresses and the corresponding thickness increase of the adhesion layer on the tank wall per unit time is obtained as the theoretical stacking constant of the adhesion layer.

[0067] The product of the latest shear stress and the theoretical stacking constant of the adhesion layer is obtained as the latest increase in the thickness of the adhesion layer on the tank wall per unit time under the latest shear stress;

[0068] The latest increase in the thickness of the adhesion layer on the tank wall per unit time is integrated within the real-time range under the latest shear stress, and the integration result is taken as the real-time thickness of the adhesion layer on the tank wall.

[0069] It should be noted that, in the embodiments of the present invention, the implementers may pre-set different shear stresses for the mixing experiment of antireflective raw materials with the same formula and analyze them.

[0070] Step S3: Obtain the actual density of the tank wall adhesion layer after simulated mixing. Combine the initial base density of the antireflective adhesive raw material, the real-time thickness of the tank wall adhesion layer, the apparent liquid level, and the morphological characteristics of the metering tank to obtain the effective volume liquid level of the antireflective adhesive raw material mixture. Based on the obtained dielectric constant of the raw material mixture, the dielectric constant and density of the pure polar component and the pure non-polar component, and the effective volume liquid level, obtain the mass equivalent liquid level of the antireflective adhesive raw material mixture.

[0071] Considering the issue of ignoring the adhesion layer leading to a level reading that meets the standard but actual raw material shortage, and given that the adhesion layer density differs from the main fluid density, the volume was corrected by analyzing the correlation between the adhesion layer density and the initial base density of the raw material. The actual density of the adhesion layer on the tank wall after simulated mixing was obtained. Combined with the initial base density of the antireflective adhesive raw material, the real-time thickness of the adhesion layer on the tank wall, the apparent liquid level, and the morphological characteristics of the metering tank, the effective volume level of the antireflective adhesive raw material mixture was determined.

[0072] Preferably, in one embodiment of the present invention, the method for obtaining the effective volume liquid level includes:

[0073] The actual density of the adhesive layer on the tank wall is obtained as a ratio to the initial base density of the antireflective adhesive raw material, which is used as the density ratio value.

[0074] The adhesion layer is equivalent to a ring-shaped cylinder. The product of the tank wall perimeter, the real-time adhesion layer thickness, and the apparent liquid level is obtained as the adhesion layer volume. The ratio of the adhesion layer volume to the density ratio is obtained as the corrected adhesion layer volume.

[0075] The ratio of the corrected volume of the adhesion layer to the cross-sectional area of ​​the tank is obtained as the equivalent deviation level of the adhesion layer; the difference between the apparent level and the equivalent deviation level of the adhesion layer is obtained as the effective volume level.

[0076] It should be noted that the inner diameter of the tank wall is measured at three locations: the upper, middle and lower parts, using a laser diameter measuring instrument. The average value is then taken as the inner diameter of the tank. The circumference of the tank wall is obtained by multiplying pi by the inner diameter of the tank. The specific method is well known to those skilled in the art and will not be described in detail here.

[0077] Antireflective coating raw materials often contain polar solvents and polar functional monomers. When the proportion of polar components increases, the dielectric polarization ability of the mixture is enhanced, and the dielectric constant increases accordingly. The polar component can be simply understood as the mixing ability of the coating raw materials. Capacitive sensors will become inaccurate due to changes in dielectric constant, and the volume calculated by ultrasound will also fail to reflect the true mass due to changes in density. Therefore, traditional liquid level measurement may lead to incorrect mixing if the changes in the dielectric properties of the mixture are not considered. Therefore, based on the dielectric constant of the raw material mixture, the dielectric constant and density of the pure polar component and the pure non-polar component, and the effective volume liquid level, the mass equivalent liquid level of the antireflective adhesive raw material mixture can be obtained.

[0078] Preferably, in one embodiment of the present invention, the method for obtaining the mass equivalent liquid level includes:

[0079] The first difference in dielectric constant between the raw material mixture and the pure nonpolar component is obtained, and the second difference in dielectric constant between the pure nonpolar component and the pure polar component is obtained. The ratio of the first difference to the second difference is calculated as the proportion of the pure polar component.

[0080] It should be noted that, in the embodiments of the present invention, the original dielectric constant of the raw material mixture is read based on a high-frequency dielectric sensor installed in the middle of the side wall of the metering tank and completely submerged 5-8 cm below the surface of the raw material liquid. The dielectric constant of the pure polar component is obtained through laboratory calibration: a pure solvent completely consistent with the production formula, such as 100% propylene glycol methyl ether acetate, is used, and the dielectric constant is continuously measured 5 times with a high-precision dielectric spectrometer under a constant temperature environment of 25°C. The average value is taken as the dielectric constant of the pure polar component. The dielectric constant of the pure non-polar component is taken from the pure resin in the formula, such as 100% phenolic resin, and measured 5 times continuously under the same constant temperature conditions and dielectric spectrometer. The average value is taken as the dielectric constant of the pure non-polar component.

[0081] Obtain the product of the proportion of pure polar components and their corresponding densities, and use it as the density contribution value of the polar components; calculate the difference between the positive integer 1 and the proportion of pure polar components, and calculate the product of the difference result and the density of pure nonpolar components, and use it as the density contribution value of the nonpolar components.

[0082] The sum of the density contribution values ​​of polar and non-polar components is obtained as the real-time mixing density; the ratio of the real-time mixing density to the preset mixing standard density is obtained, and the product of the ratio result and the effective volume liquid level is calculated as the mass equivalent liquid level of the antireflective adhesive raw material mixing.

[0083] It should be noted that, in the embodiments of the present invention, the preset mixing standard density is obtained in advance by the implementers based on the mixing situation according to the specific production requirements.

[0084] Step S4: Real-time acquisition of liquid surface image, stirring vibration power and flow rate change frequency for each frame during mixing; combined with the dielectric constant of the raw material mixture and the grayscale distribution characteristics on each frame of liquid surface image, obtain the liquid level anomaly judgment factor; based on the liquid level anomaly judgment factor and the mass equivalent liquid level, obtain the true liquid level.

[0085] Real-time acquisition of liquid surface images, stirring vibration power, and flow rate change frequency during mixing is achieved. It should be noted that, in this embodiment of the invention, a piezoelectric vibration sensor is installed at the stirring point of the calculation tank to read the stirring vibration power generated during stirring; a pulse counter is installed in the raw material feeding pump of the metering tank, and the negative correlation mapping between the time intervals of the pulses is used as the flow rate change frequency, wherein the reciprocal or exponential function with the natural constant as its base is employed. A negative correlation mapping is performed; a high-speed industrial camera is installed at the sight glass position directly above the center of the metering tank, with the lens vertically aimed at the liquid surface, to capture each frame of the page image in real time; data is acquired in real time at an acquisition frequency of 10Hz. In other embodiments of the present invention, the acquisition frequency can also be set according to specific circumstances, which will not be limited or elaborated here.

[0086] By combining the dielectric constant of the raw material mixture with the grayscale distribution characteristics on each frame of the liquid surface image, an abnormal liquid level judgment factor is obtained.

[0087] Preferably, in one embodiment of the present invention, the method for obtaining the liquid level anomaly judgment factor is described in [reference needed]. Figure 2 It shows a flowchart of a method for obtaining liquid level anomaly judgment factors, including:

[0088] Step S201: Based on the dielectric constant of the raw material mixture, the stirring vibration power, and the frequency of flow rate change during real-time mixing, obtain the liquid level correlation factor and fluctuation anomaly.

[0089] Preferably, in one embodiment of the present invention, the method for obtaining the liquid level correlation factor and fluctuation anomaly includes:

[0090] The ratio of the flow rate change frequency to the stirring vibration frequency is obtained as the liquid level correlation factor; the ratio of the fluctuation degree of the dielectric constant to the mean dielectric constant in the real-time neighborhood is obtained as the dielectric constant fluctuation rate.

[0091] The ratio of dielectric constant volatility to a preset volatility reference value is obtained and normalized to represent volatility anomalies.

[0092] It should be noted that, in one embodiment of the present invention, the degree of fluctuation of the dielectric constant is reflected by calculating the variance. The larger the variance, the greater the fluctuation, and the smaller the variance, the smaller the fluctuation. In other embodiments of the present invention, the degree of fluctuation can also be reflected by the standard deviation or the range. The specific means are well known to those skilled in the art and will not be limited or described here.

[0093] It should be noted that, in one embodiment of the present invention, the real-time neighborhood range is based on real-time data and is composed of the neighborhood range within the past 3 minutes. In other embodiments of the present invention, the size of the neighborhood range can be set according to specific circumstances, and will not be limited or elaborated here.

[0094] It should be noted that in some embodiments of the present invention, normalization can be performed by linear normalization or a normalization function. The specific means are well known to those skilled in the art and will not be described in detail here.

[0095] Step S202: Based on the gray-level distribution features on each frame of liquid surface image, obtain multiple bubble regions and gray-level co-occurrence matrix contrast on each frame of liquid surface image; obtain the fluctuation features of gray-level co-occurrence matrix contrast in different frames of liquid surface image in real time local range, and the product between the average number of bubble regions, and perform normalization mapping as the degree of liquid surface fluctuation.

[0096] It should be noted that in the embodiments of the present invention, since the reflectivity / refractive index of bubbles and liquids is different, their gray values ​​will have significant differences. The system will calculate one or more gray value thresholds and initially identify areas with gray values ​​higher or lower than the thresholds as candidate bubble areas. Using edge detection operators such as Sobel and Canny, points with abrupt changes in gray values ​​in the image are identified to form the outline of the object. In the binarized image, connected component detection is performed, and each connected component is a bubble. The gray-level co-occurrence matrix of the image is obtained, and contrast analysis is performed on the gray-level co-occurrence matrices of all images. The specific means are well known to those skilled in the art and will not be described in detail here.

[0097] It should be noted that, in one embodiment of the present invention, the local range is defined as a local range based on real-time data and the time within one minute of history. In other embodiments of the present invention, the size of the local range can be set according to specific circumstances, and will not be limited or elaborated here.

[0098] Step S203: Obtain the product of the liquid level correlation factor, fluctuation anomaly, and liquid surface fluctuation degree as the liquid level anomaly judgment factor.

[0099] Based on this, the system uses a liquid level anomaly judgment factor to determine whether the mass equivalent liquid level truly reflects the liquid level. A larger liquid level anomaly judgment factor corresponds to a higher stirring vibration frequency and greater dielectric constant fluctuation. Simultaneously, if the tank top camera captures numerous bubbles and surface disturbances, it indicates that the fluctuations are either turbulence or bubbles. Therefore, the acquisition methods include:

[0100] If the liquid level anomaly judgment factor is greater than the preset judgment threshold, the corresponding mass equivalent liquid level value will be filtered and used as the true liquid level.

[0101] Conversely, the corresponding mass equivalent liquid level value is used as the true liquid level.

[0102] It should be noted that the higher the stirring vibration frequency is than the flow rate change frequency, the easier it is to form strong turbulence. Turbulence will entrain air and generate bubbles, which may lead to abnormal liquid level. In one embodiment of the present invention, the preset judgment threshold is set to 1. In other embodiments, the size of the preset judgment threshold can be set according to the specific situation, which will not be limited or described here.

[0103] Based on this, it helps to correct measurement errors caused by the special characteristics of antireflective adhesive raw materials in real time, including factors such as high viscosity, changes in polar components, turbulence, and bubbles, and provides accurate guidance for the mixing process.

[0104] In summary, this invention obtains the actual density of the tank wall adhesion layer after simulated mixing, the initial basic density of the antireflective adhesive raw material, the real-time thickness of the tank wall adhesion layer, the apparent liquid level, and the morphological characteristics of the metering tank to obtain the effective volume liquid level of the antireflective adhesive raw material mixture. Combining the obtained dielectric constant of the raw material mixture, the dielectric constants and densities of the pure polar and pure non-polar components, the mass-equivalent liquid level of the antireflective adhesive raw material mixture is obtained. Real-time acquisition of each frame of liquid surface image, stirring vibration power, and flow rate change frequency during mixing, combined with the dielectric constant of the raw material mixture and the grayscale distribution characteristics on each frame of liquid surface image, yields a liquid level anomaly judgment factor; thus, the true liquid level is obtained. This invention accurately distinguishes between true and false liquid levels by analyzing the liquid level anomaly judgment factor, thereby correcting liquid level measurement errors in real time and improving the accuracy of liquid level detection.

[0105] This invention also proposes a metering tank, including a metering tank body, a controller, and a pressure sensor, a high-frequency dielectric sensor, a piezoelectric vibration sensor, a pulse sensor, and a high-speed industrial camera connected to the controller. The pressure sensor acquires the pressure data of the anti-reflective adhesive raw material, the high-frequency dielectric sensor acquires the dielectric constant of the raw material mixture, the piezoelectric vibration sensor acquires the stirring vibration frequency, the pulse sensor acquires the flow rate change frequency, and the high-speed industrial camera acquires each frame of liquid surface image during mixing. The control method of the controller includes:

[0106] The mixing of antireflective adhesive raw materials was simulated in a metering tank. The apparent liquid level was obtained based on the initial base density, pressure data, and gravitational acceleration of the antireflective adhesive raw materials.

[0107] Based on the variation characteristics of measured shear stress under different preset stirring power, the latest shear stress under real-time stirring power is obtained; based on the thickness growth value of the tank wall adhesion layer per unit time under different preset shear stress, the real-time adhesion layer thickness of the tank wall under the latest shear stress is obtained.

[0108] The actual density of the tank wall adhesion layer after simulated mixing is obtained. Combined with the initial base density of the antireflective adhesive raw material, the real-time thickness of the tank wall adhesion layer, the apparent liquid level, and the morphological characteristics of the metering tank, the effective volume liquid level of the antireflective adhesive raw material mixture is obtained. Based on the obtained dielectric constant of the raw material mixture, the dielectric constant and density of the pure polar component and the pure non-polar component, and the effective volume liquid level, the mass equivalent liquid level of the antireflective adhesive raw material mixture is obtained.

[0109] Real-time acquisition of liquid surface images, stirring vibration power, and flow rate change frequency for each frame during mixing; combined with the dielectric constant of the raw material mixture and the grayscale distribution characteristics on each frame of liquid surface images, to obtain a liquid level anomaly judgment factor; based on the liquid level anomaly judgment factor and the mass equivalent liquid level, to obtain the true liquid level.

[0110] It should be noted that the order of the above embodiments of the present invention is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. The processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0111] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

Claims

1. A method for detecting liquid level in the mixing of antireflective adhesive raw materials, characterized in that, The method includes: The mixing of antireflective adhesive raw materials was simulated in a metering tank. The apparent liquid level was obtained based on the initial base density, pressure data, and gravitational acceleration of the antireflective adhesive raw materials. Based on the variation characteristics of measured shear stress under different preset stirring power, the latest shear stress under real-time stirring power is obtained; based on the thickness growth value of the tank wall adhesion layer per unit time under different preset shear stress, the real-time adhesion layer thickness of the tank wall under the latest shear stress is obtained. The actual density of the tank wall adhesion layer after simulated mixing is obtained. Combined with the initial base density of the antireflective adhesive raw material, the real-time thickness of the tank wall adhesion layer, the apparent liquid level, and the morphological characteristics of the metering tank, the effective volume liquid level of the antireflective adhesive raw material mixture is obtained. Based on the obtained dielectric constant of the raw material mixture, the dielectric constant and density of the pure polar component and the pure non-polar component, and the effective volume liquid level, the mass equivalent liquid level of the antireflective adhesive raw material mixture is obtained. Real-time acquisition of liquid surface images, stirring vibration power, and flow rate change frequency for each frame during mixing; combined with the dielectric constant of the raw material mixture and the grayscale distribution characteristics on each frame of liquid surface images, to obtain a liquid level anomaly judgment factor; based on the liquid level anomaly judgment factor and the mass equivalent liquid level, to obtain the true liquid level.

2. The liquid level detection method for mixing antireflective adhesive raw materials according to claim 1, characterized in that, The method for obtaining the apparent liquid level includes: The product of the initial base density and gravitational acceleration of the antireflective adhesive raw material is obtained, and the ratio between the pressure data and the product result is used as the apparent liquid level.

3. The liquid level detection method for mixing antireflective adhesive raw materials according to claim 1, characterized in that, The method for obtaining the latest shear stress includes: Under different preset stirring power, the product of the tank cross-sectional area and the measured shear stress is obtained, and the average ratio of the product result to the corresponding preset stirring power is calculated as the standard conversion coefficient for converting stirring power into shear stress. Calculate the product of the real-time stirring power and the standard conversion factor, and then calculate the ratio of the product result to the cross-sectional area of ​​the tank as the corresponding latest shear stress.

4. The liquid level detection method for mixing antireflective adhesive raw materials according to claim 1, characterized in that, The method for obtaining the real-time adhesion layer thickness on the tank wall includes: The average value of the product between different preset shear stresses and the corresponding thickness increase of the adhesion layer on the tank wall per unit time is obtained as the theoretical stacking constant of the adhesion layer. The product of the latest shear stress and the theoretical stacking constant of the adhesion layer is obtained as the latest increase in the thickness of the adhesion layer on the tank wall per unit time under the latest shear stress; The latest increase in the thickness of the adhesion layer on the tank wall per unit time is integrated within the real-time range under the latest shear stress, and the integration result is taken as the real-time thickness of the adhesion layer on the tank wall.

5. The liquid level detection method for mixing antireflective adhesive raw materials according to claim 1, characterized in that, The method for obtaining the effective volume liquid level includes: The actual density of the adhesive layer on the tank wall is obtained as a ratio to the initial base density of the antireflective adhesive raw material, which is used as the density ratio value. The adhesion layer is equivalent to a ring-shaped cylinder. The product of the tank wall perimeter, the real-time adhesion layer thickness, and the apparent liquid level is obtained as the adhesion layer volume. The ratio of the adhesion layer volume to the density ratio is obtained as the corrected adhesion layer volume. The ratio of the corrected volume of the adhesion layer to the cross-sectional area of ​​the tank is obtained as the equivalent deviation level of the adhesion layer; the difference between the apparent level and the equivalent deviation level of the adhesion layer is obtained as the effective volume level.

6. The liquid level detection method for mixing antireflective adhesive raw materials according to claim 1, characterized in that, The method for obtaining the mass equivalent liquid level includes: Obtain the first difference in dielectric constant between the raw material mixture and the pure nonpolar component, obtain the second difference in dielectric constant between the pure nonpolar component and the pure polar component, and calculate the ratio of the first difference and the second difference as the proportion of the pure polar component. Obtain the product of the proportion of pure polar components and their corresponding densities, and use it as the density contribution value of the polar components; calculate the difference between the positive integer 1 and the proportion of pure polar components, and calculate the product of the difference result and the density of pure nonpolar components, and use it as the density contribution value of the nonpolar components. The sum of the density contribution values ​​of polar and non-polar components is obtained as the real-time mixing density; the ratio of the real-time mixing density to the preset mixing standard density is obtained, and the product of the ratio result and the effective volume liquid level is calculated as the mass equivalent liquid level of the antireflective adhesive raw material mixing.

7. The liquid level detection method for mixing antireflective adhesive raw materials according to claim 1, characterized in that, The method for obtaining the liquid level anomaly judgment factor includes: Based on the dielectric constant of the raw material mixture, the stirring vibration power, and the flow rate change frequency during real-time mixing, the liquid level correlation factor and fluctuation anomaly are obtained; Based on the gray-level distribution features on each frame of liquid surface image, multiple bubble regions and gray-level co-occurrence matrix contrast on each frame of liquid surface image are obtained; the fluctuation features of gray-level co-occurrence matrix contrast in different frames of liquid surface image in real time local range are obtained, as well as the product between the mean number of bubble regions, and normalized mapping is performed as the degree of liquid surface fluctuation. The product of the liquid level correlation factor, fluctuation anomaly, and liquid surface fluctuation degree is obtained as the liquid level anomaly judgment factor.

8. The liquid level detection method for mixing antireflective adhesive raw materials according to claim 7, characterized in that, The methods for obtaining the liquid level correlation factor and fluctuation anomaly include: The ratio of the flow rate change frequency to the stirring vibration frequency is obtained as the liquid level correlation factor; the ratio of the fluctuation degree of the dielectric constant to the mean dielectric constant in the real-time neighborhood is obtained as the dielectric constant fluctuation rate. The ratio of dielectric constant volatility to a preset volatility reference value is obtained and normalized to represent volatility anomalies.

9. The liquid level detection method for mixing antireflective adhesive raw materials according to claim 1, characterized in that, The method for obtaining the actual liquid level includes: If the liquid level anomaly judgment factor is greater than the preset judgment threshold, the corresponding mass equivalent liquid level value will be filtered and used as the true liquid level. Conversely, the corresponding mass equivalent liquid level value is used as the true liquid level.

10. A metering container, comprising a metering container body, characterized in that, It also includes a controller, and a pressure sensor, a high-frequency dielectric sensor, a piezoelectric vibration sensor, a pulse sensor, and a high-speed industrial camera connected to the controller. The pressure sensor acquires pressure data of the antireflective adhesive raw material, the high-frequency dielectric sensor acquires the dielectric constant of the raw material mixture, the piezoelectric vibration sensor acquires the stirring vibration frequency, the pulse sensor acquires the flow rate change frequency, and the high-speed industrial camera acquires each frame of liquid surface image during mixing. The control method of the controller includes: The mixing of antireflective adhesive raw materials was simulated in a metering tank. The apparent liquid level was obtained based on the initial base density, pressure data, and gravitational acceleration of the antireflective adhesive raw materials. Based on the variation characteristics of measured shear stress under different preset stirring power, the latest shear stress under real-time stirring power is obtained; based on the thickness growth value of the tank wall adhesion layer per unit time under different preset shear stress, the real-time adhesion layer thickness of the tank wall under the latest shear stress is obtained. The actual density of the tank wall adhesion layer after simulated mixing is obtained. Combined with the initial base density of the antireflective adhesive raw material, the real-time thickness of the tank wall adhesion layer, the apparent liquid level, and the morphological characteristics of the metering tank, the effective volume liquid level of the antireflective adhesive raw material mixture is obtained. Based on the obtained dielectric constant of the raw material mixture, the dielectric constant and density of the pure polar component and the pure non-polar component, and the effective volume liquid level, the mass equivalent liquid level of the antireflective adhesive raw material mixture is obtained. Real-time acquisition of liquid surface images, stirring vibration power, and flow rate change frequency for each frame during mixing; combined with the dielectric constant of the raw material mixture and the grayscale distribution characteristics on each frame of liquid surface images, to obtain a liquid level anomaly judgment factor; based on the liquid level anomaly judgment factor and the mass equivalent liquid level, to obtain the true liquid level.

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