Diluent feeding control method and system, medium and product

Abstract

The invention discloses a diluent supplementing control method and system, a medium and a product, and relates to the field of industrial automation control. By implementing the application, the control system accurately recognizes the station information and the state of the liquid storage tank through the station code, so that the whole-process monitoring and accurate control of the diluent supplementing process are realized. The control system automatically checks whether the type and the concentration of the diluent to be supplemented meet the requirements or not, and manual operation errors are avoided. The control system collects real-time weight data of the liquid storage tank and generates a weight change curve, the actual material supplementing rate can be accurately calculated and compared with the standard material supplementing rate, and abnormal conditions can be found in time. Compared with traditional liquid level control, the material supplementing control mode based on weight data is more accurate and reliable, the timeliness and accuracy of diluent supplementing can be guaranteed, and the production efficiency and the stability of product quality are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of industrial automation control, and in particular to a diluent feeding control method, a control system, a medium and a product. BACKGROUND

[0002] In the industrial fields such as semiconductor manufacturing and chemical production, the configuration and use of diluent is an important link. With the continuous improvement of industrial automation level, higher requirements are put forward for the accurate control of diluent feeding process, especially in some production processes with strict requirements on diluent concentration and usage, it is necessary to ensure the stable operation and timely replenishment of diluent storage system.

[0003] At present, an automatic feeding system is generally used for diluent feeding control in industrial production, that is, the automatic feeding system monitors the liquid level of the liquid storage tank in real time through a liquid level sensor, and sets a feeding start point and a feeding stop point. When the liquid level of the liquid storage tank is lower than the feeding start point, the feeding pump is started to deliver diluent to the liquid storage tank, and when the liquid level of the liquid storage tank reaches the feeding stop point, the feeding is automatically stopped.

[0004] This liquid level control method has some limitations in practical application. Since the feeding start and stop are controlled only by the change of liquid level during the feeding process, the running state of the feeding equipment is difficult to be effectively monitored, and once the automatic feeding system appears abnormal fluctuation, it may affect the production efficiency. SUMMARY

[0005] The present application provides a diluent feeding control method, a control system, a medium and a product for ensuring the timeliness and accuracy of diluent feeding.

[0006] In a first aspect, the present application provides a diluent feeding control method applied to a control system, the method comprising: determining station information and corresponding liquid storage tank weight data according to a station code, the station information comprising a station number, diluent specification parameters and a standard feeding rate, the diluent specification parameters comprising a first type, a first concentration and a minimum limit weight of the diluent; if the liquid storage tank weight data is lower than the minimum limit weight, collecting diluent information to be supplemented in a feeding container, the diluent information to be supplemented comprising a second type and a second concentration of the diluent; performing consistency verification on the first type and the second type, and conformity verification on the first concentration and the second concentration; when the consistency verification and the conformity verification are both passed, opening a feeding valve and continuously collecting real-time weight data of the liquid storage tank according to a preset sampling period, and generating a weight change curve according to the real-time weight data; calculating an actual feeding rate based on the weight change curve, and determining a feeding state parameter as a ratio of the actual feeding rate to the standard feeding rate; continuously feeding when the feeding state parameter is greater than or equal to a preset parameter threshold, until the real-time weight data of the liquid storage tank reaches a preset target weight, and the preset target weight is set based on the minimum limit weight.

[0007] By adopting the technical scheme, the control system accurately identifies the station information and the liquid storage tank state through the station code, realizes whole-process monitoring and accurate control of the diluent replenishment process, automatically checks whether the type and concentration of the diluent to be replenished meet the requirements, and avoids human operation errors. The control system collects real-time weight data of the liquid storage tank and generates a weight change curve, can accurately calculate an actual replenishment rate, and compares the actual replenishment rate with a standard replenishment rate to discover abnormal conditions in time. Compared with traditional liquid level control, the replenishment control mode based on weight data is more accurate and reliable, can ensure timeliness and accuracy of diluent replenishment, and improves production efficiency and stability of product quality.

[0008] In combination with some embodiments of the first aspect, in some embodiments, after the step of collecting diluent-to-be-replenished information in the replenishment container, the diluent-to-be-replenished information including a second type and a second concentration of the diluent, if the weight data of the liquid storage tank is lower than the minimum limit weight, the method further includes: acquiring weight data of the replenishment container, and comparing the weight data of the replenishment container with a preset lower capacity limit; if the weight data of the replenishment container is lower than the preset lower capacity limit, recording the replenishment container number and sending a replenishment container replacement instruction; if the weight data of the replenishment container is higher than or equal to the preset lower capacity limit, calculating an available replenishment amount and generating replenishment task parameters.

[0009] By adopting the technical scheme, weight detection is performed on the replenishment container before replenishment, when the replenishment container inventory is insufficient, a replenishment container replacement instruction is automatically sent, and interruption of the replenishment process is avoided, when the replenishment container capacity is sufficient, an available replenishment amount is calculated and replenishment task parameters are generated, so that the replenishment process is more controllable. This front-end container monitoring mechanism can timely alert and take measures, effectively reducing production interruptions caused by replenishment container problems, and improving production continuity and equipment utilization.

[0010] In combination with some embodiments of the first aspect, in some embodiments, before the step of opening the replenishment valve and continuously collecting real-time weight data of the liquid storage tank according to a preset sampling period, and generating a weight change curve according to the real-time weight data, when the consistency check and the compliance check are both passed, the method further includes: acquiring a PH value and a conductivity of the diluent in the liquid storage tank, determining a diluent quality feature vector based on the PH value and the conductivity; performing similarity calculation on the diluent quality feature vector and a preset standard quality feature vector; when the similarity is lower than a preset similarity threshold, triggering a liquid storage tank cleaning process.

[0011] By adopting the above technical solution, the pH value and conductivity of the diluent in the storage tank are detected before replenishment, and the similarity between the diluent quality feature vector and the preset standard quality feature vector is calculated, thus achieving intelligent monitoring of the diluent quality. When an abnormality in the diluent quality is detected, the control system automatically triggers a cleaning process, preventing the continued use of substandard diluent. This multi-parameter-based diluent quality monitoring mechanism can comprehensively assess the diluent status, promptly detect and address quality issues, effectively ensure the stability of the quality of production materials, and reduce product quality risks caused by fluctuations in diluent quality.

[0012] In conjunction with some embodiments of the first aspect, in some embodiments, the method further includes: determining the diluent consumption rate of each workstation based on historical operating data; calculating the predicted replenishment time window for each workstation based on the diluent consumption rate; calculating the replenishment priority of each workstation by using the predicted replenishment time window, workstation importance, and the travel distance between the replenishment equipment and the workstation as input parameters; and performing replenishment operations in descending order of workstation replenishment priority when multiple workstations need to be replenished simultaneously.

[0013] By adopting the above technical solution, the control system analyzes historical operating data, calculates the diluent consumption rate of each workstation, and predicts the replenishment time window based on this. Simultaneously, it establishes a scientific workstation replenishment priority evaluation system by combining multiple dimensions such as workstation importance and the travel distance between the replenishment equipment and the workstation. When multiple workstations require replenishment simultaneously, the control system can rationally schedule the replenishment sequence, avoiding the risk of material shortages at critical workstations that may arise from the traditional first-come, first-served approach. This intelligent replenishment scheduling mechanism ensures timely supply to important workstations, optimizes the operating path of the replenishment equipment, improves overall replenishment efficiency, and reduces the risk of production anomalies.

[0014] In conjunction with some embodiments of the first aspect, in some embodiments, the diluent consumption rate of each workstation is determined based on historical operating data, specifically including: determining the cumulative diluent usage of each workstation within the effective recording days based on historical operating data; dividing the cumulative diluent usage by the effective recording days to obtain the average daily usage; dividing the average daily usage by the standard working hours to obtain the baseline consumption rate of each workstation; and correcting the baseline consumption rate according to the production load coefficient of each workstation to obtain the diluent consumption rate.

[0015] By adopting the above technical solution, the control system has established an accurate calculation model for the consumption rate of diluent at the workstation. It fully considers the influencing factors such as time span, working duration and load changes, making the prediction of diluent consumption rate more accurate, providing a reliable basis for the formulation of replenishment plans, and effectively reducing the situation of untimely or excessive replenishment.

[0016] In conjunction with some embodiments of the first aspect, in some embodiments, the predicted replenishment time window, workstation importance, and travel distance between the replenishment equipment and the workstation are used as input parameters to calculate the workstation replenishment priority. Specifically, this includes: calculating the time urgency based on the predicted replenishment time window of the current workstation, the largest predicted replenishment time window among all workstations, and the smallest predicted replenishment time window among all workstations; calculating the workstation importance based on the basic weight coefficient of the current workstation, the planned output of the current workstation, and the maximum planned output of all workstations; calculating the distance influence index based on the travel distance from the replenishment equipment to the current workstation, the maximum travel distance from the replenishment equipment to each workstation, and the minimum travel distance from the replenishment equipment to each workstation; and determining the workstation replenishment priority based on the time urgency, workstation importance, and distance influence index.

[0017] By adopting the above technical solution, the control system constructed a workstation replenishment priority calculation model based on multi-dimensional indicators. Through calculating three core indicators—time urgency, workstation importance, and distance impact index—it achieved precise quantification of replenishment priority. Time urgency reflects the urgency of replenishment, workstation importance reflects production importance, and the distance impact index optimizes equipment scheduling efficiency. This approach ensures both the timeliness of replenishment and optimal resource allocation, significantly improving replenishment scheduling efficiency in multi-workstation scenarios.

[0018] In conjunction with some embodiments of the first aspect, in some embodiments, after the steps of calculating the actual feeding rate based on the weight change curve and determining the ratio of the actual feeding rate to the standard feeding rate as the feeding status parameter, the method further includes: when the feeding status parameter is less than a preset parameter threshold, determining that the feeding is abnormal, closing the feeding valve and triggering an alarm signal.

[0019] By adopting the above technical solution, the control system monitors the feeding status parameters in real time, establishing a timely and effective early warning mechanism for feeding anomalies. When the ratio of the actual feeding rate to the standard feeding rate is lower than a preset parameter threshold, the control system can quickly determine the feeding anomaly and take measures such as valve closure and alarm. This anomaly monitoring method based on rate comparison can detect and handle feeding anomalies in time before the problem escalates, avoiding material waste or equipment damage caused by feeding anomalies.

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

[0023] Understandably, the 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 methods 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: 1. By adopting the above technical solution, the control system accurately identifies workstation information and storage tank status through workstation codes, achieving full monitoring and precise control of the diluent replenishment process. The control system automatically verifies whether the type and concentration of the diluent to be replenished meet the requirements, avoiding human error. The control system collects real-time weight data from the storage tank and generates a weight change curve, which can accurately calculate the actual replenishment rate and compare it with the standard replenishment rate to promptly detect abnormalities. This weight data-based replenishment control method is more accurate and reliable than traditional level control, ensuring the timeliness and accuracy of diluent replenishment, and improving production efficiency and product quality stability.

[0025] 2. By adopting the above technical solution, the pH value and conductivity of the diluent in the storage tank are detected before replenishment, and the similarity between the diluent quality feature vector and the preset standard quality feature vector is calculated, thus realizing intelligent monitoring of the diluent quality. When an abnormality in the diluent quality is detected, the control system automatically triggers a cleaning process, preventing the continued use of unqualified diluent. This multi-parameter-based diluent quality monitoring mechanism can comprehensively assess the diluent status, promptly detect and handle quality problems, effectively ensure the stability of the quality of production materials, and reduce the product quality risk caused by fluctuations in diluent quality.

[0026] 3. By adopting the above technical solution, the control system analyzes historical operating data, calculates the diluent consumption rate of each workstation, and predicts the replenishment time window based on this. Simultaneously, by combining multiple dimensions such as workstation importance and the travel distance between the replenishment equipment and the workstation, a scientific workstation replenishment priority evaluation system is established. When multiple workstations require replenishment simultaneously, the control system can rationally schedule the replenishment sequence, avoiding the risk of material shortages at critical workstations that may arise from the traditional first-come, first-served approach. This intelligent replenishment scheduling mechanism ensures timely supply to important workstations, optimizes the operating path of the replenishment equipment, improves overall replenishment efficiency, and reduces the risk of production anomalies. Attached Figure Description

[0027] Figure 1 This is a flowchart illustrating a diluent replenishment control method in an embodiment of this application; Figure 2 This is another flowchart illustrating the diluent replenishment control method in the embodiments of this application; Figure 3 This is a schematic diagram of the physical device structure of a 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 of this application, the singular expressions “a,” “an,” “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 any or all possible combinations including 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] The following describes the process of the method provided in this implementation. Please refer to [link / reference]. Figure 1 This is a flowchart illustrating a diluent replenishment control method in an embodiment of this application.

[0031] S101. Determine the work station information and the corresponding liquid storage tank weight data according to the work station code. The work station information includes the work station number, diluent specification parameters and standard replenishment rate. The diluent specification parameters include the first type, first concentration and minimum weight limit of the diluent. Among them, the workstation code is the coded information used to uniquely identify a specific workstation on the production line, such as "WP001", "WP002", etc.; workstation information refers to the set of basic configuration data related to a specific workstation; workstation number is used to indicate the serial number of the workstation on the production line, such as "workstation 1", "workstation 2", etc.; diluent specification parameters refer to the set of parameters describing the basic characteristics of the diluent required for this workstation; the first type refers to the chemical category of the diluent required by the standard process of this workstation, such as "sulfuric acid", "hydrofluoric acid", etc.; the first concentration refers to the concentration value of the diluent required by the standard process of this workstation, such as "10%", "20%", etc.; the minimum weight limit indicates the weight threshold at which the storage tank needs to be replenished; the standard replenishment rate refers to the standard flow rate when the workstation is replenished normally, such as "2kg / min"; and the storage tank weight data indicates the current actual weight value of the storage tank.

[0032] Specifically, the control system reads the workstation code using an RFID reader or barcode scanner installed at the workstation and accesses the database to obtain the workstation information corresponding to that workstation code, including the workstation number, diluent specifications (type, concentration, etc.), and standard replenishment rate. Simultaneously, the control system collects real-time weight data of the storage tank via a weighing sensor connected to the storage tank.

[0033] S102. If the weight data of the storage tank is lower than the minimum weight limit, collect the information of the diluent to be replenished in the replenishment container. The information of the diluent to be replenished includes the second type and the second concentration of the diluent. Among them, the replenishment container refers to the container equipment used to store the diluent to be replenished, such as a material barrel or storage tank; the information of the diluent to be replenished refers to the set of characteristic parameters of the diluent to be replenished; the second type refers to the chemical category of the diluent in the replenishment container; and the second concentration refers to the actual concentration value of the diluent in the replenishment container.

[0034] Specifically, the control system obtains information about the diluent to be replenished in the replenishment container through an electronic tag reader installed on the container, including parameters such as the type and concentration of the diluent. For smart replenishment containers, the control system can directly read this information through a digital interface; for ordinary replenishment containers, the control system obtains this information by scanning a QR code or barcode on the container.

[0035] S103. Perform consistency verification between the first type and the second type, and perform compliance verification between the first concentration and the second concentration; Among them, consistency verification refers to the verification process of whether the two diluents are of the same type; compliance verification refers to the verification process of whether the second concentration meets the first concentration.

[0036] Specifically, the control system precisely matches the type of diluent required at the workstation (Type 1) with the actual type of diluent in the replenishment container (Type 2) to ensure complete consistency. Subsequently, the control system checks whether the actual concentration of the diluent in the replenishment container (Type 2 concentration) meets the concentration specification required at the workstation (Type 1 concentration). The control system typically allows the actual concentration to fluctuate within ±1% of the concentration specification. The verification is considered successful only when the types are perfectly matched and the concentration is within the allowable range. This dual verification mechanism effectively prevents incorrect replenishment.

[0037] S104. When both the consistency check and the compliance check pass, open the feeding valve and continuously collect the real-time weight data of the storage tank according to the preset sampling cycle, and generate a weight change curve based on the real-time weight data. Among them, the feeding valve refers to the electric valve device used to control the flow of diluent; the preset sampling period refers to the time interval at which the control system collects real-time weight data of the storage tank, such as "500ms" or "1s"; the real-time weight data refers to the instantaneous weight value of the storage tank during the feeding process; the weight change curve refers to the trend graph plotted with time as the horizontal axis and weight as the vertical axis; the consistency check refers to the matching verification of the diluent type; and the compliance check refers to the specification verification of the diluent concentration.

[0038] Specifically, the control system sends an opening command to the feed valve control unit, and the feed valve opens to a preset degree. The control system continuously collects real-time weight data of the storage tank using a high-precision weighing sensor at a preset sampling period (typically 500ms). The data for each sampling point includes a timestamp and the corresponding weight value. The control system arranges the collected real-time weight data of the storage tank in a time series and generates a smooth weight change curve using a spline interpolation algorithm. This weight change curve reflects the dynamic changes in the weight of the storage tank during the feed process and is used for subsequent feed rate calculations and anomaly monitoring.

[0039] S105. Calculate the actual feeding rate based on the weight change curve, and determine the ratio of the actual feeding rate to the standard feeding rate as the feeding state parameter. The actual replenishment rate refers to the actual increase in the weight of the storage tank per unit time, expressed in kg / min; the standard replenishment rate represents the standard replenishment flow rate specified by the process; and the replenishment status parameter is the ratio of the actual replenishment rate to the standard replenishment rate, used to characterize the stability of the replenishment process.

[0040] Specifically, the control system calculates the slope of the weight change curve using data from the most recent 30 seconds and converts this slope into the actual replenishment rate. The control system updates the calculation results every 5 seconds, comparing the latest actual replenishment rate with the standard replenishment rate for that station to obtain the replenishment status parameter. This parameter reflects the degree to which the actual replenishment process conforms to the standard process requirements. Typically, this parameter is required to be maintained within the range of 0.9-1.1, indicating a stable replenishment process.

[0041] S106. When the feeding status parameter is greater than or equal to the preset parameter threshold, feeding continues until the real-time weight data of the storage tank reaches the preset target weight, which is based on the minimum weight limit setting.

[0042] Among them, the preset parameter threshold refers to the standard value for determining whether the feeding process is normal, which is usually 0.9; the preset target weight represents the expected weight value of the storage tank.

[0043] Specifically, the control system compares the replenishment status parameters with a preset threshold (typically 0.9). When the replenishment status parameters are greater than or equal to the preset threshold, it indicates that the replenishment process is normal, and the control system maintains the replenishment valve open. The control system dynamically calculates the preset target weight based on the minimum weight limit, typically setting it to 150% of the minimum weight limit to ensure a reasonable replenishment margin. The control system continuously monitors the real-time weight data of the storage tank. When the real-time weight data reaches the preset target weight, it automatically closes the replenishment valve, completing the replenishment task.

[0044] By adopting the above technical solution, the control system accurately identifies workstation information and storage tank status through workstation codes, achieving full monitoring and precise control of the diluent replenishment process. The control system automatically verifies whether the type and concentration of the diluent to be replenished meet the requirements, avoiding human error. The control system collects real-time weight data from the storage tank and generates a weight change curve, accurately calculating the actual replenishment rate and comparing it with the standard replenishment rate to promptly detect anomalies. This weight-data-based replenishment control method is more accurate and reliable than traditional level control, ensuring the timeliness and accuracy of diluent replenishment, and improving production efficiency and product quality stability.

[0045] The following provides a more detailed description of the process of the method provided in this implementation. Please refer to [link / reference]. Figure 2 This is another flowchart illustrating the diluent replenishment control method in this application embodiment.

[0046] S201. Determine the workstation information and corresponding liquid storage tank weight data based on the workstation code. The workstation information includes the workstation number, diluent specification parameters, and standard replenishment rate. The diluent specification parameters include the first type, first concentration, and minimum weight limit of the diluent.

[0047] For details, please refer to step S101, which is not limited here.

[0048] S202. Obtain the pH value and conductivity of the diluent in the storage tank, and determine the quality feature vector of the diluent based on the pH value and conductivity.

[0049] Among them, pH value refers to the acidity or alkalinity of the diluent, which is used to characterize the acidity or alkalinity of the diluent; conductivity refers to the measure of the conductivity of the diluent, with the unit being μS / cm, which is used to characterize the ion concentration in the diluent; the diluent quality feature vector is a two-dimensional numerical vector composed of pH value and conductivity, which is used to comprehensively characterize the quality status of the diluent.

[0050] Specifically, when the diluent in the storage tank is in a static state, the control system collects the pH value and conductivity of the diluent through a pH probe and conductivity sensor installed at the bottom or inside the storage tank. The control system performs signal filtering and temperature compensation processing on the collected raw data to obtain corrected pH value and conductivity. Subsequently, the control system constructs a diluent quality feature vector by using the corrected pH value as the first dimension component and the corrected conductivity as the second dimension component. For example, if the measured pH value is 5.2 and the conductivity is 156 μS / cm, then the diluent quality feature vector is [5.2, 156].

[0051] S203. Calculate the similarity between the quality feature vector of the diluent and the preset standard quality feature vector.

[0052] Among them, the preset standard quality feature vector is used to represent the quality parameter vector of the diluent under the ideal state specified by the process specification, which consists of standard pH value and standard conductivity; similarity refers to the degree of closeness between the diluent quality feature vector and the preset standard quality feature vector, with a value range of [0, 1], and the larger the value, the closer they are.

[0053] Specifically, the control system reads the preset standard quality feature vector of this type of diluent from the database. For each diluent, the database stores its pH value and conductivity under standard conditions. For example, the preset standard quality feature vector [5.0, 150] indicates a standard pH value of 5.0 and a standard conductivity of 150 μS / cm. The control system uses a cosine similarity algorithm to calculate the actual measured quality feature vector of the diluent with the preset standard quality feature vector. The control system first normalizes the two vectors to eliminate the influence of dimensions, then calculates the dot product of the normalized vectors, and finally divides the result by the product of the magnitudes of the two vectors to obtain the final similarity. For example, when the actual measured quality feature vector of the diluent is [5.2, 156], the calculated similarity is 0.9986, which will be used for subsequent quality judgment.

[0054] S204. When the similarity is lower than the preset similarity threshold, the liquid storage tank cleaning process is triggered.

[0055] The preset similarity threshold is the standard value for determining whether the quality of the diluent is qualified, usually set to 0.95; the storage tank cleaning process refers to a series of cleaning and maintenance operations for the storage tank, including steps such as draining, filling with water, and circulating flushing.

[0056] Specifically, the control system compares the calculated similarity with a preset similarity threshold (e.g., 0.95). When the similarity is lower than the preset threshold, it indicates a significant deviation in the quality of the diluent. The control system then sends a cleaning prompt to the human-machine interface and automatically closes the inlet and outlet valves of the storage tank. Subsequently, the control system starts the storage tank drainage pump to discharge the abnormal diluent into the waste liquid collection system and opens the cleaning water inlet valve to inject a specified amount of deionized water into the storage tank. The control system then starts the stirring device to perform circulating cleaning. After cleaning, the pH value and conductivity of the cleaning water in the storage tank are checked again. Only after confirming that the standards are met can the tank be put back into use.

[0057] S205. If the weight data of the storage tank is lower than the minimum limit, collect the information of the diluent to be replenished in the replenishment container. The information of the diluent to be replenished includes the second type and the second concentration of the diluent.

[0058] For details, please refer to step S102, which is not limited here.

[0059] S206. Obtain the weight data of the replenishment container and compare the weight data of the replenishment container with the preset lower limit of capacity.

[0060] The weight data of the replenishment container refers to the total weight of the replenishment container and the diluent inside it, in kg; the preset capacity lower limit refers to the minimum remaining amount of diluent in the replenishment container, which is used to ensure the continuity of the replenishment process.

[0061] Specifically, the control system collects the weight data of the replenishment container in real time through a high-precision weighing sensor mounted on the base of the replenishment container. The control system filters and zero-point calibrates the collected digital signal, converting the processed digital signal into an actual weight value. The control system compares this actual weight value with a preset lower capacity limit (usually 50kg), and the comparison result is used to determine whether the replenishment container needs to be replaced.

[0062] S207. If the weight data of the replenishment container is lower than the preset capacity limit, record the replenishment container number and send a replenishment container replacement instruction.

[0063] The replenishment container number refers to the serial number used to uniquely identify the replenishment container, such as "TC001"; the replenishment container replacement command refers to the command that triggers the replenishment container replacement process.

[0064] Specifically, when the control system detects that the weight of the replenishment container is lower than the preset capacity limit (the difference between the preset target weight and the real-time weight of the storage tank), it automatically reads the RFID tag or barcode information of the replenishment container to obtain the container number, and writes the container number, the current weight data, and the time into the system log. Simultaneously, the control system sends a replacement command to the replenishment management system and displays a replacement prompt on the operating terminal. The control system also activates an audible and visual alarm to remind on-site operators to replace the replenishment container promptly, ensuring the continuity of the replenishment operation.

[0065] S208. If the weight data of the replenishment container is higher than or equal to the preset lower limit of capacity, calculate the available replenishment amount and generate replenishment task parameters.

[0066] The available replenishment quantity refers to the actual weight of diluent that can be used in the replenishment container; the replenishment task parameters refer to the various configuration parameters used to control the replenishment process, including the replenishment rate and target weight.

[0067] Specifically, when the control system confirms that the weight data of the replenishment container meets the requirements, the available replenishment amount is the preset lower limit of capacity, which is the difference between the preset target weight and the real-time weight data of the storage tank. The control system combines the available replenishment amount with the standard replenishment rate to calculate the expected replenishment time. Based on this, the control system generates complete replenishment task parameters, including the target replenishment weight, replenishment rate, and expected replenishment time.

[0068] S209. Perform consistency verification between the first type and the second type, and perform compliance verification between the first concentration and the second concentration.

[0069] For details, please refer to step S103, which is not limited here.

[0070] S210. When both the consistency check and compliance check pass, open the feeding valve and continuously collect real-time weight data of the storage tank according to the preset sampling cycle, and generate a weight change curve based on the real-time weight data.

[0071] For details, please refer to step S104, which is not limited here.

[0072] S211. Calculate the actual feeding rate based on the weight change curve, and determine the ratio of the actual feeding rate to the standard feeding rate as the feeding state parameter.

[0073] For details, please refer to step S105, which is not limited here.

[0074] S212. When the feeding status parameter is greater than or equal to the preset parameter threshold, feeding continues until the real-time weight data of the storage tank reaches the preset target weight, which is based on the minimum weight limit setting.

[0075] For details, please refer to step S106, which is not limited here.

[0076] S213. When the feeding status parameter is less than the preset parameter threshold, the feeding is determined to be abnormal, the feeding valve is closed and an alarm signal is triggered.

[0077] Among them, the preset parameter threshold refers to the standard value for determining whether the feeding process is normal, which is usually set to 0.9; feeding abnormality refers to the state where the actual feeding rate does not meet the standard feeding rate; alarm signals include system alarm prompts and on-site audible and visual alarms.

[0078] Specifically, the control system continuously monitors the feeding status parameters. When the feeding status parameters are detected to be lower than the preset threshold, the control system determines that an anomaly has occurred in the current feeding process. At this time, the control system immediately sends a shut-off command to the feeding valve control unit to cut off the diluent supply. Simultaneously, an anomaly alarm message is displayed on the operating interface, and the on-site audible and visual alarm device is activated. The control system records the time of the anomaly, the feeding status parameters, and other information, and notifies maintenance personnel to inspect the feeding equipment to ensure timely detection and handling of any potential faults.

[0079] S214. Determine the diluent consumption rate for each workstation based on historical operating data.

[0080] Historical operating data refers to the diluent usage records of each workstation over a period of time; diluent consumption rate refers to the amount of diluent consumed by each workstation per unit time.

[0081] Specifically, the control system extracts historical operating data for each workstation from the database. First, the control system calculates the cumulative diluent usage for each workstation during the effective recording period, then divides it by the number of effective recording days to obtain the average daily usage. Next, the control system divides the average daily usage by the standard working hours to obtain the baseline consumption rate for each workstation. Finally, the control system adjusts the baseline consumption rate based on the current production load coefficient of each workstation to obtain a diluent consumption rate that better reflects the actual situation.

[0082] Optionally, under normal circumstances, the diluent consumption rate of each workstation can be determined based on historical operating data in the following ways, without limitation: Based on historical operating data, determine the cumulative diluent usage of each workstation within the effective recording days; divide the cumulative diluent usage by the effective recording days to obtain the average daily usage; divide the average daily usage by the standard working hours to obtain the baseline consumption rate of each workstation; and correct the baseline consumption rate according to the production load coefficient of each workstation to obtain the diluent consumption rate.

[0083] For example, for workstation 1, the control system extracts its historical operating data for the past 30 days and finds that the cumulative diluent usage is 3000 kg. The control system divides 3000 kg by 30 days to obtain an average daily usage of 100 kg / day. Then, assuming a standard working time of 8 hours, the control system divides 100 kg / day by 8 hours to obtain a baseline consumption rate of 12.5 kg / hour. Finally, if the production load factor for workstation 1 over these 30 days is 1.2 (indicating a 20% increase in workload than normal), the control system multiplies the baseline consumption rate of 12.5 kg / hour by 1.2, ultimately obtaining an actual diluent consumption rate of 15 kg / hour for this workstation. This corrected diluent consumption rate more accurately reflects the actual diluent demand of this workstation under the current production conditions.

[0084] S215. Based on the diluent consumption rate, calculate the predicted replenishment time window for each station.

[0085] The predicted replenishment time window refers to the time interval during which the next replenishment is expected; the calculation process takes into account factors such as the current liquid storage volume, consumption rate, and safety stock.

[0086] Specifically, the control system calculates the available diluent volume based on the current liquid level and minimum weight limit of the storage tanks at each workstation. Then, it divides the available diluent volume by the corrected diluent consumption rate to obtain the expected diluent availability time. Based on this available diluent availability time, the control system considers factors such as production plan fluctuations and replenishment equipment scheduling to determine the predicted replenishment time window for each workstation.

[0087] S216. Using the predicted replenishment time window, workstation importance, and the travel distance between the replenishment equipment and the workstation as input parameters, calculate the workstation replenishment priority.

[0088] Among them, workstation importance refers to the degree of importance of the workstation in the production process, which is related to production capacity and product value; travel distance refers to the actual distance that the material replenishment equipment travels to each workstation; and workstation material replenishment priority is the material replenishment order calculated based on multiple factors.

[0089] Optionally, in general, the predicted replenishment time window, workstation importance, and travel distance between the replenishment equipment and the workstation are used as input parameters. The workstation replenishment priority can be calculated in the following ways, without limitation: Calculate the time urgency based on the predicted replenishment time window of the current workstation, the largest predicted replenishment time window among all workstations, and the smallest predicted replenishment time window among all workstations; calculate the workstation importance based on the basic weight coefficient of the current workstation, the planned output of the current workstation, and the maximum planned output of all workstations; calculate the distance influence index based on the travel distance from the replenishment equipment to the current workstation, the maximum travel distance from the replenishment equipment to each workstation, and the minimum travel distance from the replenishment equipment to each workstation; and determine the workstation replenishment priority based on the time urgency, workstation importance, and distance influence index.

[0090] The following explanation uses three workstations as an example, assuming the control system currently acquires the following data: Workstation 1: The predicted replenishment time window is 2 hours later, the basic weight coefficient is 0.8, the planned output is 400 pieces, and the distance to the replenishment equipment is 50 meters. Workstation 2: The predicted replenishment time window is 4 hours later, the basic weight coefficient is 1.0, the planned output is 600 pieces, and the distance to the replenishment equipment is 30 meters. Workstation 3: The predicted replenishment time window is 1 hour later, the basic weight coefficient is 0.6, the planned output is 300 pieces, and the distance to the replenishment equipment is 80 meters. Calculation process: 1. Time urgency calculation: Maximum time window is 4 hours, minimum time window is 1 hour; Workstation 1: (4-2) / (4-1) = 0.67; Workstation 2: (4-4) / (4-1)=0; Workstation 3: (4-1) / (4-1) = 1; 2. Workstation importance calculation: Maximum planned output 600 units; Workstation 1: 0.8 × (400 / 600) = 0.53; Workstation 2: 1.0 × (600 / 600) = 1.0; Workstation 3: 0.6 × (300 / 600) = 0.3; 3. Distance Influence Index Calculation: Maximum distance 80 meters, minimum distance 30 meters; Workstation 1: (80-50) / (80-30) = 0.6; Workstation 2: (80-30) / (80-30) = 1.0; Workstation 3: (80-80) / (80-30)=0; 4. Assuming the weights of the three indicators are 0.4, 0.4, and 0.2 respectively, the final priority score is: Workstation 1: 0.67×0.4+0.53×0.4+0.6×0.2=0.6; Workstation 2: 0 × 0.4 + 1.0 × 0.4 + 1.0 × 0.2 = 0.6; Workstation 3: 1×0.4+0.3×0.4+0×0.2=0.52; According to the calculation results, station 1 and station 2 have the same and higher priority, while station 3 has a lower priority. During actual material replenishment, the order of station 1 and station 2 can be further determined based on other factors (such as process requirements).

[0091] S217. When multiple workstations need to replenish materials simultaneously, the replenishment operation shall be performed in descending order of the workstation replenishment priority.

[0092] Specifically, when the control system detects that multiple workstations require diluent replenishment within the same time period, it obtains the replenishment priority score for each workstation. The control system sorts the workstations according to their replenishment priority scores from highest to lowest, generating a replenishment sequence list. Based on this replenishment sequence list, the control system dispatches replenishment equipment to the corresponding workstations to perform the replenishment task. For each replenishment task, the control system monitors the replenishment process in real time to ensure that the replenishment operation is completed according to process requirements, while simultaneously preparing for the next workstation to be replenished.

[0093] The control system in the embodiments of this invention is described below from the perspective of hardware processing. Please refer to [link / reference needed]. Figure 3 This is a schematic diagram of the physical device structure of the control system in an embodiment of this application.

[0094] It should be noted that, Figure 3 The structure of the control system shown is merely an example and should not impose any limitation on the functionality and scope of use of the embodiments of the present invention.

[0095] like Figure 3As shown, the control system includes a CPU 301, which can perform various appropriate actions and processes based on a program stored in the read-only memory ROM 302 or a program loaded from the storage section 308 into the random access memory RAM 303, such as executing the methods described in the above embodiments. The RAM 303 also stores various programs and data required for system operation. The CPU 301, ROM 302, and RAM 303 are interconnected via a bus 304. An I / O interface 305 is also connected to the bus 304. The following components are connected to I / O interface 305: input section 306 including audio input devices, push-button switches, etc.; output section 307 including a liquid crystal display (LCD) and audio output devices, indicator lights, etc.; storage section 308 including a hard disk, etc.; and communication section 309 including a network interface card such as a LAN (Local Area Network) card, modem, etc. The communication section 309 performs communication processing via a network such as the Internet. Drive 310 is also connected to I / O interface 305 as needed. Removable media 311, such as a disk, optical disk, magneto-optical disk, semiconductor memory, etc., are installed on drive 310 as needed so that computer programs read from them can be installed into storage section 308 as needed. In particular, according to embodiments of the present invention, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments of the present invention include a computer program product comprising a computer program carried on a computer-readable medium, the computer program containing computer programs for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via communication section 309, and / or installed from removable medium 311. When the computer program is executed by CPU 301, it performs the various functions defined in the present invention.

[0096] It should be noted that specific examples of computer-readable storage media may include, but are not limited to: electrical connections having one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), flash memory, optical fiber, portable compact disc read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof. In this invention, a computer-readable storage medium can be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, apparatus, or device.

[0097] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. Each block in a flowchart or block diagram may represent a module, program segment, or portion of code, which contains one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those shown in the drawings.

[0098] Specifically, the control system of this embodiment includes a processor and a memory. The memory stores a computer program. When the computer program is executed by the processor, it implements the diluent replenishment control method provided in the above embodiment.

[0099] In another aspect, the present invention also provides a computer-readable storage medium, which may be included in the control system described in the above embodiments; or it may exist independently and not incorporated into the control system. The storage medium carries one or more computer programs that, when executed by a processor of the control system, cause the control system to implement the diluent replenishment control method provided in the above embodiments.

[0100] 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.

[0101] As used in the above embodiments, depending on the context, the term "when..." can be interpreted as meaning "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 meaning "if determining...", "in response to determining...", "when (the stated condition or event) is detected", or "in response to detecting (the stated condition or event)".

[0102] 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 method for controlling the feeding of diluent, characterized in that, Applied to a control system, the method includes: The workstation information and the corresponding liquid storage tank weight data are determined according to the workstation code. The workstation information includes the workstation number, diluent specification parameters and standard replenishment rate. The diluent specification parameters include the first type, first concentration and minimum weight limit of the diluent. If the weight data of the storage tank is lower than the minimum weight limit, the information of the diluent to be replenished in the replenishment container is collected. The information of the diluent to be replenished includes the second type and the second concentration of the diluent. A consistency check is performed between the first type and the second type, and a conformity check is performed between the first concentration and the second concentration; When both the consistency check and the compliance check pass, the feeding valve is opened and real-time weight data of the storage tank is continuously collected according to the preset sampling period, and a weight change curve is generated based on the real-time weight data. The actual feeding rate is calculated based on the weight change curve, and the ratio of the actual feeding rate to the standard feeding rate is determined as the feeding state parameter. When the replenishment status parameter is greater than or equal to the preset parameter threshold, replenishment continues until the real-time weight data of the storage tank reaches the preset target weight, which is based on the minimum weight limit.

2. The method according to claim 1, characterized in that, After the step of collecting information on the diluent to be replenished in the replenishment container when the weight data of the storage tank is lower than the minimum weight limit, wherein the information on the diluent to be replenished includes the second type and second concentration of the diluent, the method further includes: Obtain the weight data of the replenishment container and compare the weight data of the replenishment container with a preset lower capacity limit; If the weight of the replenishment container is lower than the preset capacity limit, record the replenishment container number and send a replenishment container replacement instruction; If the weight data of the replenishment container is higher than or equal to the preset lower capacity limit, the available replenishment amount is calculated and replenishment task parameters are generated.

3. The method according to claim 1, characterized in that, Before the steps of opening the feeding valve and continuously collecting real-time weight data of the storage tank according to a preset sampling period when both the consistency check and the compliance check pass, and generating a weight change curve based on the real-time weight data, the method further includes: Obtain the pH value and conductivity of the diluent in the storage tank, and determine the quality feature vector of the diluent based on the pH value and conductivity; The similarity between the quality feature vector of the diluted solution and the preset standard quality feature vector is calculated. When the similarity is lower than a preset similarity threshold, the liquid storage tank cleaning process is triggered.

4. The method according to claim 1, characterized in that, The method further includes: Based on historical operating data, determine the diluent consumption rate for each workstation; Based on the diluent consumption rate, the predicted replenishment time window for each station is calculated; The predicted replenishment time window, workstation importance, and travel distance between the replenishment equipment and the workstation are used as input parameters to calculate the workstation replenishment priority. When multiple workstations need to be replenished simultaneously, the replenishment operation is performed in descending order of workstation replenishment priority.

5. The method according to claim 4, characterized in that, The process of determining the diluent consumption rate for each workstation based on historical operational data specifically includes: Based on the historical operational data, determine the cumulative amount of diluent used at each workstation within the valid recording days; Divide the cumulative amount of diluent used by the number of valid record days to obtain the average daily usage. Divide the average daily usage by the standard working hours to obtain the baseline consumption rate of each workstation; The baseline consumption rate is corrected based on the production load coefficient of each workstation to obtain the diluent consumption rate.

6. The method according to claim 4, characterized in that, The step of calculating the workstation replenishment priority by using the predicted replenishment time window, workstation importance, and the travel distance between the replenishment equipment and the workstation as input parameters specifically includes: Calculate the time urgency based on the current workstation's predicted replenishment time window, the largest predicted replenishment time window among all workstations, and the smallest predicted replenishment time window among all workstations. The importance of a workstation is calculated based on its basic weight coefficient, its planned output, and the maximum planned output of all workstations. The distance influence index is calculated based on the travel distance from the replenishing equipment to the current workstation, the maximum travel distance from the replenishing equipment to each workstation, and the minimum travel distance from the replenishing equipment to each workstation. The material replenishment priority of the workstation is determined based on the time urgency, the importance of the workstation, and the distance impact index.

7. The method according to claim 1, characterized in that, After the steps of calculating the actual replenishment rate based on the weight change curve and determining the ratio of the actual replenishment rate to the standard replenishment rate as a replenishment state parameter, the method further includes: When the feeding status parameter is less than the preset parameter threshold, the feeding is determined to be abnormal, the feeding valve is closed and an alarm signal is triggered.

8. A control system, characterized in that, The 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 control system to perform the method as described in any one of claims 1-7.

9. A computer-readable storage medium comprising instructions, characterized in that, When the instruction is executed on the control system, it causes the control system to perform the method as described in any one of claims 1-7.

10. A computer program product, characterized in that, When the computer program product is run on the control system, the control system performs the method as described in any one of claims 1-7.

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