Cooperative control system for filling electric cylinder and adjustable stirring cylinder

Abstract

The invention relates to the technical field of automatic packaging equipment, and discloses a cooperative control system for a filling electric cylinder and an adjustable stirring cylinder. The system comprises a filling electric cylinder module, a weighing measurement module, an adjustable stirring cylinder module and a cooperative controller module. The filling electric cylinder module executes the filling action and feeds back the position speed; the weighing measurement module collects the material weight of the container in real time and converts the material weight into liquid level height; the adjustable stirring cylinder module stirs materials through variable frequency driving and replaceable paddles; and the cooperative controller module receives real-time data of each module and SPC historical data, analyzes and generates a cooperative control instruction, and dynamically optimizes filling and stirring parameters. By means of modular integration and data closed-loop control, high-precision and self-adaptive filling is achieved, the problems that traditional equipment is difficult to adjust, insufficient in precision, poor in material adaptability and lack of intelligent feedback are solved, and the high-precision self-adaptive filling device is suitable for occasions with high requirements for filling precision and flexibility in the industries of food, medicine and the like.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automatic packaging equipment, in particular to a filling electric cylinder and adjustable stirring cylinder cooperative control system. BACKGROUND

[0002] Quantitative filling of materials in food and similar industries is a basic link to realize product standardization and production automation. The current widely used filling technology mainly relies on fixed metering pumps, piston cylinders or basic weighing methods to complete material supply and metering. These traditional methods have exposed several significant problems in actual production operation.

[0003] The maintenance of filling accuracy is challenging. Most existing system structures exhibit rigid characteristics and lack the ability to dynamically adjust according to actual field conditions. For example, the position of the filling container may deviate slightly, the characteristics of the material itself (such as viscosity, temperature, whether it contains bubbles) may also change within or between batches, and the remaining amount of material in the storage cylinder decreases, causing pressure changes. In the face of these common environmental or working condition fluctuations, traditional systems cannot real-time perceive and adjust filling parameters (such as piston stroke, filling speed), leading to actual filling quantity easily deviating from the preset target value. This deviation directly affects product quality consistency and raw material utilization rate.

[0004] Real-time monitoring and feedback accuracy during the filling process is insufficient. Most existing devices rely on indirect means such as photoelectric sensors or float switches to detect the liquid level height in the container. This method is difficult to directly and accurately reflect the actual weight of the filled material or the precise liquid level position. Factors such as material surface fluctuations, container transparency differences, and bubble interference can significantly affect the reliability of such indirect measurement, making it difficult to accurately control the filling end point, ultimately affecting the accuracy of the filling result.

[0005] The homogenization processing capacity of the material before filling is limited. A filling device usually needs to handle multiple materials with different physical properties, such as low-viscosity water-based agents, high-viscosity sauces or pastes, and easily precipitated and layered suspensions. Traditional stirring cylinders often use fixed stirring parameters (speed, paddle type, start and stop time), which are difficult to adapt to such diverse material characteristics. For easily precipitated, layered or high-viscosity materials, the lack of effective and parameter-adjustable stirring mechanisms can lead to inconsistent material states in the storage cylinder, causing differences in composition or concentration between products filled before and after, affecting the uniformity of the final product.

[0006] The existing system generally lacks intelligent decision-making and closed-loop optimization capabilities based on production data. A large amount of process data is generated during the production process, such as weight deviation of each filling, filling time, environmental temperature, etc. Although some advanced devices introduce elements such as servo drive, these improvements are often limited to the improvement of a single functional module, and fail to organically connect the sensing (weight, position), analysis (historical data, deviation trend), decision-making (parameter adjustment), and execution (filling, stirring) links in the entire filling process to form a self-adaptive closed-loop control system. Without effectively utilizing the analysis results based on historical batch data such as SPC (Statistical Process Control), the system is difficult to predict and compensate potential deviation trends, and has weak self-adaptive ability, relying on frequent manual intervention and experience adjustment for continuous optimization of the production process. This situation limits the further improvement of production efficiency and the stable guarantee of product quality. SUMMARY

[0007] The purpose of the present application is to provide a filling electric cylinder and adjustable stirring cylinder cooperative control system to solve the problems raised in the background art.

[0008] To achieve the above-mentioned purpose, the present application provides a filling electric cylinder and adjustable stirring cylinder cooperative control system, which comprises:

[0009] a filling electric cylinder module for performing a filling action and feeding back position and speed data in real time;

[0010] a weighing measurement module for collecting the total weight of the container and the material in real time and converting it into a liquid level value;

[0011] an adjustable stirring cylinder module for variable frequency stirring of the material in the storage cylinder through replaceable stirring paddles;

[0012] a cooperative controller module for receiving the real-time liquid level value of the weighing measurement module, the position and speed data of the filling electric cylinder module, and the stirring state data of the adjustable stirring cylinder module, and generating a cooperative control instruction based on SPC historical data analysis.

[0013] Preferably, the weighing measurement module transmits the total weight of the container and the material collected in real time to the cooperative controller module;

[0014] The cooperative controller module converts the total weight of the container and the material into a real-time liquid level value according to a pre-set material density parameter, and triggers a dynamic compensation mechanism based on the deviation value between the real-time liquid level value and the target liquid level value.

[0015] Preferably, the cooperative controller module comprises an SPC data analysis unit, which generates a filling total amount compensation value based on the mean and standard deviation of the filling deviation of the previous N times;

[0016] The filling total amount compensation value satisfies a positive balance condition that the filling total amount compensation value is not less than a preset filling deviation threshold.

[0017] Preferably, the synergic controller module generates a cylinder stroke fine-tuning instruction and a speed fine-tuning instruction according to the filling total amount compensation value.

[0018] The filling cylinder module adjusts the displacement parameter of the filling valve based on the cylinder stroke fine-tuning instruction and the speed fine-tuning instruction.

[0019] Preferably, the adjustable stirring cylinder module sends a current stirring paddle type identifier and a real-time rotating speed value to the synergic controller module.

[0020] The synergic controller module matches a stirring intensity coefficient corresponding to the stirring paddle type identifier based on a material characteristic database.

[0021] Preferably, the synergic controller module generates a segmented rotating speed instruction set according to the stirring intensity coefficient.

[0022] The adjustable stirring cylinder module executes a first rotating speed instruction in a filling preparation stage, a second rotating speed instruction in a filling execution stage, and a third rotating speed instruction in a filling completion stage.

[0023] Preferably, the synergic controller module compares the speed data of the filling cylinder module with the real-time rotating speed value of the adjustable stirring cylinder module in real time.

[0024] When the filling speed change rate exceeds a preset fluctuation threshold, a stirring rotating speed compensation instruction is generated to the adjustable stirring cylinder module.

[0025] Preferably, the synergic controller module divides the filling process into three synergic control window periods, i.e., a preparation stage, a main filling stage, and a supplementary filling stage.

[0026] Each synergic control window period corresponds to a different mapping relationship between the displacement parameter of the filling cylinder and the rotating speed parameter of the adjustable stirring cylinder.

[0027] Preferably, in the supplementary filling stage window period, the weighing measurement module starts a weight change continuous monitoring mode.

[0028] The synergic controller module dynamically switches the high-speed mode and the slow-speed mode of the filling cylinder according to the weight change continuous monitoring data.

[0029] Preferably, the synergic controller module generates a synergic effect evaluation parameter based on the error rate of the final filling liquid level height value and the target liquid level height value, the filling total amount compensation value execution result, and the stirring rotating speed matching degree.

[0030] The synergic effect evaluation parameter is used to update the historical data record set of the SPC data analysis unit.

[0031] Compared with the prior art, the present application has the following advantages:

[0032] The filling electric cylinder and adjustable stirring cylinder collaborative control system integrates three core functional modules of filling execution, weight monitoring and material homogenization, and uses process data to make intelligent decisions through a collaborative controller, thereby realizing overall performance improvement of the filling process. The system accurately executes the filling action by the filling electric cylinder module and feeds back real-time position and speed information, directly obtains the total weight of the container material by the weighing and measuring module and converts it into an intuitive liquid level, adjusts the stirring cylinder module through frequency drive and replaceable stirring paddles to adapt to the stirring requirements of different materials, and the collaborative controller comprehensively processes real-time data and historical statistical information to generate optimized collaborative control instructions sent to each module.

[0033] The core value of the system lies in establishing a data closed loop from perception to execution. The collaborative controller can receive and analyze the real-time liquid level changes provided by the weighing module, the position and speed state fed back by the filling electric cylinder module and the operating parameters of the stirring cylinder, and combine the stored SPC historical data to evaluate the current filling process. Based on the evaluation result, the controller generates adjustment instructions to dynamically optimize the operating parameters of the filling electric cylinder and the working state of the stirring cylinder, so that the system can adapt to fluctuations in site conditions such as material property changes and container positioning differences, and improve the consistency of the filling result.

[0034] The weighing and measuring module directly provides weight information and converts it into a liquid level display, eliminating the indirectness and uncertainty brought by traditional photoelectric or floating ball detection methods. The operator can intuitively master the filling progress and result, simplifying the operation and monitoring process. The frequency control and diversified paddle options of the adjustable stirring cylinder module give the system the ability to handle a wide range of material types. Whether it is a liquid with good flowability, a suspension prone to sedimentation or a paste with high viscosity, the system can call or automatically match the corresponding stirring strategy to ensure that the material remains in good homogenization state in the storage cylinder.

[0035] The whole system reduces the dependence on manual experience judgment and manual parameter adjustment in the production process. The collaborative controller automatically adjusts parameters based on real-time feedback and historical data analysis, making the filling process self-adaptive. The operator's main responsibility shifts to monitoring the system status and handling a small number of abnormal alarms, significantly reducing the frequency and intensity of manual intervention and improving production automation. The system supports storage and quick calling of formulas. When switching to produce different products or using different containers, the operator can conveniently call the pre-set complete parameter combination (including target filling amount, electric cylinder operation curve, stirring parameters, etc.) through the human-machine interface, shorten the changeover time, improve the equipment's adaptability to multi-variety and small-batch production mode, and enhance the flexibility of production organization.

[0036] The system adopts a modular design concept, and each core function module (filling cylinder, weighing sensor unit, stirring drive) is relatively independent and has a clear interface. This clear design structure facilitates daily maintenance and maintenance work, simplifies the replacement process of key components, helps to shorten the equipment downtime, and maintains the continuity of production. The design of the system meets the relevant industry hygiene and safety specification requirements. The structure is compact, reduces the dead angle of material residue, the material selection is easy to clean and disinfect, can meet the basic requirements of GMP (Good Manufacturing Practice) and food safety production, and help to ensure the hygiene and safety quality of the final product. BRIEF DESCRIPTION OF DRAWINGS

[0037] Figure 1 A working principle diagram of a filling cylinder and an adjustable stirring cylinder cooperative control system according to the present application;

[0038] Figure 2 A flowchart of the working of the weighing measurement and dynamic compensation mechanism;

[0039] Figure 3 A flowchart of the generation and execution of the segmented speed instruction set;

[0040] Figure 4 A flowchart of the generation of the stirring speed compensation instruction. DETAILED DESCRIPTION

[0041] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0042] Please refer to Figure 1 The present application provides a filling cylinder and an adjustable stirring cylinder cooperative control system, which comprises. The filling cylinder and the adjustable stirring cylinder cooperative control system is composed of a filling cylinder module, a weighing measurement module, an adjustable stirring cylinder module and a cooperative controller module.

[0043] The filling cylinder module performs the filling action by driving the filling valve or piston head through a servo electric cylinder, and integrates a high-resolution encoder to feed back position and speed data in real time. The weighing measurement module installs a high-precision weighing sensor under the filling station tray to collect the total weight of the container and material in real time, and converts it into the liquid level value through density conversion or calibration curve. The adjustable mixing cylinder module integrates a variable frequency or servo controlled mixing motor in the storage cylinder to drive the replaceable mixing paddle (anchor type, spiral type or paddle type) to mix the material, with a speed range of 50-1500 rpm. The cooperative controller module receives the real-time liquid level value of the weighing measurement module, the position and speed data of the filling cylinder module, and the mixing state data of the adjustable mixing cylinder module (including mixing paddle type identification and real-time speed value), and generates cooperative control instructions based on the filling deviation mean, standard deviation and other data in the SPC historical database to achieve dynamic optimization of filling parameters.

[0044] Example 1: refer to Figure 2 The weighing measurement module collects total weight data of the container and material in real time through a high-precision weighing sensor. The weighing sensor adopts a strain gauge or electromagnetic force balance structure, is installed under the load tray of the filling station, has a range of 0-50 kg, and a resolution of 0.01 g. The module continuously acquires weight signals at a sampling frequency of 10 Hz, which are transmitted to the cooperative controller module after being converted by a 24-bit ADC. The cooperative controller module has a built-in material density parameter database that stores the density values of different materials (such as detergent 1.02 g / mL, ink 1.25 g / mL) and container calibration parameters (container empty weight, inner diameter size). When the weight data is transmitted, the system performs the following conversion process:

[0045] Container net weight elimination: subtract the preset container empty weight value from the total weight;

[0046] Material mass calculation: divide the net weight value by the material density parameter to obtain the current material volume;

[0047] Liquid level conversion: according to the container inner diameter size (cylindrical container uses the formula H = V / (πr 2 , and the height-volume table is called for special-shaped containers), output the real-time liquid level value (unit: mm).

[0048] The cooperative controller module compares the real-time liquid level value with the preset target liquid level value in real time to generate a deviation value (AH = H 实测 - H 目标 ). When |AH| exceeds the preset deviation threshold (e.g. ±0.5 mm), the dynamic compensation mechanism triggers in two stages:

[0049] The first stage (slow feeding control): when the filling amount reaches 90% of the target value, the collaborative controller module sends instructions to the filling cylinder module to switch the filling speed from the reference value (e.g., 50 mm / s) to the slow mode (e.g., 10 mm / s). This stage reduces the risk of overshoot caused by inertia by reducing the cylinder propulsion rate.

[0050] The second stage (travel compensation correction): if the deviation value still exists in the slow mode (e.g., ΔH > 0.3 mm for 3 consecutive samples), the collaborative controller module calls the SPC historical data analysis unit to generate a compensation amount based on the deviation mean of the previous 30 fillings. For example, if the historical mean shows a continuous negative deviation (underfilling), calculate the additional compensation travel (e.g., +0.07 mm) and issue a cylinder travel fine-tuning instruction. The filling cylinder module superimposes this compensation value in the remaining travel through the servo motor until the filling is completed.

[0051] The weighing measurement module synchronously performs anti-interference processing: a digital filter (e.g., moving average filter) is used to eliminate transient fluctuations caused by mechanical vibration; the ambient temperature is collected through a temperature sensor, and the weighing drift is compensated according to the temperature-sensitivity coefficient reference table. All weight data is time-stamped and strictly synchronized with the position data (encoder pulse count) and speed data (pulse frequency) of the filling cylinder, ensuring the timing consistency of the liquid level calculation. The trigger record of the dynamic compensation mechanism (including deviation threshold breakthrough time, compensation amount, final correction result) is written into the SPC database for subsequent statistical process control model optimization.

[0052] After receiving the compensation instruction, the filling cylinder module adjusts the motion curve of the servo motor in real time. For example, when the travel fine-tuning instruction takes effect, the motor driver increases the compensation displacement amount based on the original target position, and dynamically calculates the acceleration curve according to the remaining filling amount to avoid material splashing caused by sudden stop. The weighing measurement module starts the high-frequency sampling mode (50 Hz) during the compensation filling stage to monitor the weight change trend in real time. When the fluctuation of 5 consecutive sampling data is less than 0.02 g, it is determined that the filling is completed stably, and the collaborative controller module terminates the compensation process and closes the filling valve. The whole process realizes accurate control of the liquid level through real-time data closed loop without manual intervention for parameter adjustment.

[0053] Example 2: The SPC data analysis unit of the collaborative controller module extracts filling record data from a historical database. The database stores information of recently completed filling jobs in a ring buffer structure, each record contains fields such as filling batch number, target fill volume, actual fill volume, environmental temperature and humidity, material type, etc. The SPC data analysis unit performs data preprocessing: first, it eliminates obviously abnormal records (such as jobs with deviations exceeding ±5% caused by filling interruptions or manual intervention), then it performs statistical analysis on the deviation values of the last N valid filling records (N defaults to 30 and can be configured). The deviation value is defined as the difference between the actual fill volume (final value collected by the weighing measurement module) and the target fill volume. The system calculates the arithmetic mean (μ) and standard deviation (σ) of this data set, where the mean reflects the systematic deviation trend (such as consistently overfilling or underfilling), and the standard deviation reflects the random fluctuation amplitude.

[0054] Based on the calculation results, the SPC data analysis unit calls a preset compensation model library. The model library contains three core algorithms: a proportional compensation model (compensation amount = k x μ, k is a correction coefficient related to the material), a moving average prediction model (predicts the current deviation based on the weighted average of the last M deviations), and a neural network prediction model (inputs include historical deviations, environmental parameters, and material viscosity). The system automatically matches the model according to the current material type, for example, high-viscosity materials preferentially select the neural network model. After selecting the model, μ and σ are used as input variables to generate a total fill compensation value. This value must satisfy the positive equilibrium condition: the absolute value of the compensation amount must be greater than the preset fill deviation threshold (for example, 0.1g), otherwise it is considered as noise interference and not adopted. For example, if μ = -0.15g and σ = 0.08g, the proportional model (k = 0.9) outputs a compensation value of +0.135g, which satisfies the threshold condition; if μ = -0.05g and σ = 0.02g, the compensation value is ignored.

[0055] The collaborative controller module converts the total fill compensation value into execution instructions. The compensation value is first decomposed into two dimensions:

[0056] Electric cylinder stroke fine-tuning instruction: based on the cross-sectional area of the filling valve and the material density, the compensation mass value is converted into an incremental piston displacement (for example, +0.135g of ink corresponds to a 0.03mm piston advance);

[0057] Speed fine-tuning instruction: dynamically adjust the filling speed based on the deviation trend. If historical data shows that overshooting (negative μ value) is prone to occur at the end of filling, a deceleration instruction is generated (such as reducing the reference speed of 50mm / s by 5% to 47.5mm / s); if there is a persistent underfilling (positive μ value), an acceleration instruction is generated (such as increasing the reference speed of 50mm / s by 5% to 52.5mm / s).

[0058] After receiving the instructions, the filling electric cylinder module executes the adjustments in stages:

[0059] Main filling stage (filling amount 0%-90%): advance according to the original set stroke and speed, without compensation;

[0060] Compensation trigger stage (filling amount 90%-100%): superimpose a fine stroke (e.g. +0.03mm) on the original target stroke end point, while the speed is adjusted according to the fine instruction. After receiving the displacement increment, the servo motor driver dynamically corrects the position loop target value and executes the remaining stroke with the new speed parameter. For example, when the piston reaches the 90% position of the original stroke, the target position register of the motor controller is updated in real time to "original end point coordinate +0.03mm", while the speed instruction register writes a parameter of 47.5mm / s. The encoder monitors the actual displacement with a resolution of 0.01mm to ensure that the compensation amount is accurately implemented.

[0061] Data during compensation execution is monitored in real time: the weighing measurement module collects weight data at a frequency of 20Hz during the compensation stage, and the controller module compares the compensation expected value with the actual increment in real time. When the filling end signal is triggered (weight fluctuation <0.02g for three consecutive sampling times), the system records the actual filling amount of this time, calculates the final deviation value, and writes the following information into the SPC database: original compensation instruction value, actual compensation execution amount, final deviation, environmental parameters. These data are used for subsequent self-optimization of the compensation model: for example, if the deviation still exceeds the limit after five consecutive compensations, the system automatically increases the correction coefficient k or switches the prediction model. The whole process is completed in a single filling cycle without manual intervention.

[0062] Example 3: refer to Figure 3 The adjustable stirring cylinder module automatically detects the installation state of the stirring paddle when it is started. The stirring paddle shaft is integrated with an RFID tag at the end, which stores the paddle type code and geometric parameters (such as diameter, blade angle). When the stirring motor is powered on, the radio frequency reader reads the tag data and analyzes the stirring paddle type identification (for example, anchor paddle code "A01-250" represents a diameter of 250mm anchor paddle). The identification and real-time speed value of the stirring motor (collected by the motor encoder at a frequency of 100Hz) are transmitted to the cooperative controller module through the industrial bus. The cooperative controller module queries the built-in material property database, which is stored in a two-dimensional table structure, with the material type code as the row index (such as paste code P01, suspension code S02) and the stirring paddle type identification as the column index. The cell data includes the stirring intensity coefficient (dimensionless parameter) and the recommended speed range.

[0063] The matching logic of stirring intensity coefficient η is as follows: if there is a complete match in the database (such as material P01 and paddle type A01-250), the corresponding η value (such as 1.2) is directly called; if there is no complete match, the η value of the same type of stirring paddle (anchor type) with different sizes is searched according to the paddle type similarity (such as η of A01-200 is 1.0 and η of A01-300 is 1.5); the η value of the current size is calculated by interpolation according to the paddle diameter ratio (the interpolation result of 250 mm is 1.35); if there is no record of the material type, the default coefficient η = 1.0 is selected.

[0064] Based on the η value and the target material characteristics, the controller module generates a segmented speed instruction set. The instruction set includes control parameters of three stages:

[0065] The first speed instruction: the filling preparation stage (material pre-stirring period), the speed calculation formula is:

[0066] N1 = N base × η × α

[0067] Wherein: N base is the reference speed (such as 800 rpm); η is the stirring intensity coefficient; α is the pre-stirring intensification factor (default 1.5). For example, when η = 1.2, N1 = 1440 rpm is calculated, and the duration is a preset value determined by the material viscosity (high viscosity material is extended to 60 seconds).

[0068] The second speed instruction: the filling execution stage, the speed N2 takes the minimum value of the material flowability maintenance:

[0069]

[0070] Wherein: β is the flow maintenance factor (the higher the viscosity, the smaller the β value, such as β = 1.0 for high viscosity material → N2 = 800 rpm).

[0071] The third speed instruction: the filling completion stage, the speed N3 = 100-300 rpm anti-settling speed, and the specific value is set according to the material settling rate.

[0072] After the instruction is issued, the stirring motor realizes speed switching by using vector control. In the filling preparation stage, the motor accelerates from static to N1, and the acceleration slope is limited by the material splashing risk level (such as 500 rpm / s acceleration rate for paste). When the filling execution stage trigger condition (such as filling cylinder displacement > 5 mm) is reached, the controller immediately sends N2 instruction to the stirring driver. The speed switching process uses S-curve acceleration and deceleration algorithm to avoid torque jump. The stirring motor encoder feedbacks the actual speed in real time, and the controller compares the set value with the measured value every 10 ms. If the deviation of 20 consecutive sampling periods exceeds ±2%, it is determined that the load is abnormal (such as paddle jam), and the torque compensation current output is triggered.

[0073] Parameter update flow during material switching: When the operator selects a new material type (e.g. from P01 to S02) on the HMI, the system performs: calls the viscosity class and settling parameters of the new material; retrieves the database to update the agitation intensity coefficient η (e.g. η = 0.8 for S02 suspension); recalculates the segmented speed command set (N1 = 800 x 0.8 x 1.5 = 960 rpm, N2 = 800 / 0.8 = 1000 rpm); if the current installed agitator is not suitable for the new material (e.g. anchor blade is prone to shear damage for suspension), the HMI pops up a warning to replace the blade type. The entire parameter update is completed within 300 ms without the need for downtime intervention. All speed setpoints, actual values and switching events during operation are recorded in the process database for SPC analysis module to call.

[0074] Example 4: Referring to Figure 4 , the cooperative controller module divides a single filling operation into three cooperative control window periods: preparation phase, main filling phase, and supplementary filling phase. Each window period corresponds to a specific mapping relationship of the filling cylinder displacement parameter and the adjustable agitator speed parameter. Referring to Table 1, taking the filling of jam (high viscosity material) as an example, the system calls the preset parameter configuration table during initialization.

[0075] Table 1: Cooperative control window period parameter mapping table (jam filling).

[0076]

[0077]

[0078] When the filling start signal is triggered (e.g. the HMI start button is pressed), the system enters the preparation phase: the filling cylinder module resets the piston to the 0 mm position, and the agitator cylinder executes pre-agitation at a speed of 1200 rpm (for 30 seconds). The cylinder displacement sensor (encoder) monitors the position change in real time, and when the displacement exceeds 5 mm, the cooperative controller module automatically switches to the main filling phase. In this phase, the filling cylinder advances the piston at a speed of 40 mm / s, while the agitator cylinder speed is reduced to 600 rpm to maintain the material flowability. The agitator motor encoder feeds back the real-time speed value at a frequency of 100 Hz, and the cooperative controller module collects this data every 20 ms, and compares it with the speed data of the filling cylinder (calculated through the pulse frequency of the servo motor encoder) in real time.

[0079] Cooperative controller module built-in dynamic fluctuation monitoring algorithm: Calculate the filling speed change rate, take the speed data of 10 consecutive sampling periods (200 ms), calculate the standard deviation; if the standard deviation exceeds the preset fluctuation threshold (15% for jam scenario), it is determined that the material flowability is abnormal. For example, when the filling speed data sequence is [38.5, 36.2, 31.7, 28.4, 25.1] mm / s (unit period attenuation > 3 mm / s), the standard deviation reaches 18.4% exceeding the threshold, the system immediately generates a stirring speed compensation instruction. The instruction contains two dimensions: incremental direction, if the speed shows a downward trend (viscosity increases), the compensation instruction is to increase the speed; compensation amount, calculated in proportion to the deviation, for example, 3.4% exceeding the threshold corresponds to a 5% speed increase (600 rpm x 105% = 630 rpm).

[0080] The compensation instruction is issued to the adjustable stirring cylinder module within 5 ms. After receiving the new set value, the stirring driver uses S-curve acceleration mode (instead of step jump) to increase the speed from 600 rpm to 630 rpm, and the acceleration time is controlled within 300 ms to avoid torque impact. During speed adjustment, the cooperative controller module continuously monitors the filling speed change rate: if the standard deviation falls within the threshold in the next 3 periods, maintain the compensated speed; if it still does not improve, start secondary compensation (such as another 5% increase to 661 rpm).

[0081] Data interaction process of window period switching and compensation mechanism: When the cylinder displacement reaches 180 mm (end point of main filling stage), the displacement sensor triggers an interrupt signal, and the cooperative controller module switches to the compensation filling stage; the compensation filling stage cylinder speed is reduced to 8 mm / s, and the stirring cylinder maintains the current compensated speed (e.g. 630 rpm); the weighing measurement module simultaneously starts high-frequency sampling of weight (50 Hz), and when the weight change rate < 0.1 g / s is detected, it is determined that the filling is complete and the filling valve is closed; all window period events (switching time point, compensation trigger times, final speed value) are recorded to the operation log for traceability analysis.

[0082] Abnormal scenario processing: If the speed fluctuation still exceeds the limit after three consecutive compensations in the main filling stage (for example, if the jam contains solid particles causing blockage), the cooperative controller module executes the safety strategy: pause the filling cylinder advance and close the filling valve; increase the stirring cylinder speed to 800 rpm (clearing mode) for 10 seconds; reset to the starting point of the main filling stage to reattempt filling. If the second attempt fails, trigger the device alarm and notify manual intervention. The whole process maintains the stability of the parameter mapping relationship in each stage through timing cooperation and dynamic response.

[0083] Example 5: During the filling stage window, the weighing measurement module starts the weight change continuous monitoring mode. This mode will increase the sampling frequency from the regular 10Hz to 50Hz, and enable the dedicated filter algorithm to eliminate the transient mechanical vibration interference. The weighing sensor output signal is converted by 24-bit high-precision ADC, and the real-time total weight data of the container and material is transmitted to the collaborative controller module. The collaborative controller module performs weight increment analysis: the weight change value AW(current weight minus last cycle weight) is calculated every 20ms, and compared with the preset rate threshold (for example, if the sauce filling is set to 1.5g / s). When AW is greater than the threshold for three consecutive sampling values, the filling electric cylinder maintains high-speed mode (8mm / s); when AW is less than 0.5g / s for two consecutive sampling values and the difference between the current total weight and the target weight is ≤2g, the slow-speed mode switching instruction is triggered. At this time, the filling electric cylinder speed is reduced to 2mm / s, and the filling valve opening angle is reduced by 50% synchronously to prevent overshoot.

[0084] After the end of the filling stage, the collaborative controller module collects three groups of key data:

[0085] Final filling liquid level height value: according to the last weight data of the weighing measurement module, combined with the inner diameter parameter of the container to calculate the actual liquid level height;

[0086] Filling total amount compensation value execution result: compare the compensation instruction issued by the SPC data analysis unit (such as +0.135g) with the actual deviation correction amount (for example, calculate that this filling is more than the target value by 0.12g through weighing data);

[0087] Stirring speed matching degree: extract the stirring cylinder set speed during the filling stage (such as 630rpm) and the average value of the encoder feedback speed (such as 625.3rpm), and calculate the absolute deviation percentage.

[0088] Based on the above data, the collaborative effect evaluation parameters are generated:

[0089] Liquid level height error rate: |actual height value-target height value| / target height value x 100%;

[0090] Compensation fit degree: 1-(compensation instruction value-actual correction amount) / compensation instruction value (if the instruction value is zero, this item is not counted);

[0091] Speed matching deviation: |set speed-actual speed average| / set speed x 100%.

[0092] The collaborative controller module uses a weighted algorithm to synthesize the comprehensive evaluation parameter: the error rate weight accounts for 50%;

[0093] The compensation fit degree weight is 30% (if there is no compensation instruction, the weight is distributed to the error rate); the speed matching deviation weight is 20%.

[0094] For example, when the error rate is 0.15%, the compensation goodness of fit is 95%, and the rotational speed matching deviation is 0.7%, the comprehensive score is calculated to be 98.7 (in percentage). The score is written into the historical data record set of the SPC database, and is stored in association with the following metadata: material type and viscosity grade; environmental temperature and humidity; filling batch number and time stamp.

[0095] The SPC data analysis unit calls the evaluation parameters to perform model optimization: when the comprehensive score of five consecutive batches is greater than 95, the current compensation model parameters are maintained; when the score is in the interval of 90-95, the weighted coefficient of the moving average model is adjusted; when the score is less than 90, the neural network model retraining process is triggered: the last 100 groups of filling data (including error rate, compensation goodness of fit, environmental parameters, etc.) are extracted, and the model weight matrix is updated.

[0096] If a single score is lower than a preset qualified line (such as 80), the system performs an abnormal marking: suspending the current production line filling process; activating the fault diagnosis module to compare the operation parameter differences between the abnormal batch and the historical high-quality batch; and popping up an alarm code and a suggested troubleshooting item (such as "low compensation goodness of fit → check the zero point drift of the weighing sensor") on the HMI interface. All score data and optimization records generate a monthly trend report for use in device maintenance decision-making. The entire evaluation mechanism realizes a closed-loop iteration from single filling feedback to long-term strategy adjustment.

[0097] It should be noted that, in the present document, relational terms such as first and second and the like can be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises", "comprising", or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0098] While embodiments of the present application have been shown and described with reference to certain explanations, it is understood that those skilled in the art can make various changes, modifications, replacements and variations to the embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A filling and adjustable stirring cylinder cooperative control system, characterized in that, The application relates to a filling system, which comprises the following modules: a filling cylinder module for performing a filling action and feeding back position and speed data in real time; a weighing measurement module for collecting the total weight of a container and material in real time and converting the total weight into a liquid level value; an adjustable stirring cylinder module for stirring material in a storage cylinder through variable frequency stirring of replaceable stirring paddles; and a cooperative controller module for receiving the real-time liquid level value of the weighing measurement module, the position and speed data of the filling cylinder module and the stirring state data of the adjustable stirring cylinder module, and generating a cooperative control instruction based on SPC historical data analysis. The weighing measurement module transmits the total weight of the container and material collected in real time to the cooperative controller module. The cooperative controller module converts the total weight of the container and material into a real-time liquid level value according to a preset material density parameter, and triggers a dynamic compensation mechanism based on the deviation value of the real-time liquid level value and a target liquid level value. The cooperative controller module comprises an SPC data analysis unit which generates a total filling compensation value based on the mean value and standard deviation of filling deviations in the previous N times. The total filling compensation value needs to satisfy a positive balance condition that the total filling compensation value is not less than a preset filling deviation threshold.

2. The system of claim 1, wherein the controller is configured to control the filling cylinder and the adjustable mixing cylinder based on the measured pressure of the fluid in the filling cylinder. The cooperative controller module generates cylinder stroke fine-tuning instructions and speed fine-tuning instructions according to the total filling compensation value. The filling cylinder module adjusts the displacement parameters of a filling valve based on the cylinder stroke fine-tuning instructions and speed fine-tuning instructions.

3. The system of claim 2, wherein the controller is configured to control the filling cylinder and the adjustable mixing cylinder based on the measured pressure of the fluid in the filling cylinder. The adjustable stirring cylinder module sends the current stirring paddle type identification and real-time rotating speed value to the cooperative controller module. The cooperative controller module matches the stirring intensity coefficient corresponding to the stirring paddle type identification based on a material characteristic database.

4. The system of claim 3, wherein the controller is configured to control the filling cylinder and the adjustable mixing cylinder based on the measured pressure of the fluid in the filling cylinder. The cooperative controller module generates a segmented rotating speed instruction set according to the stirring intensity coefficient. The adjustable stirring cylinder module executes a first rotating speed instruction in a filling preparation stage, a second rotating speed instruction in a filling execution stage and a third rotating speed instruction in a filling completion stage.

5. The system of claim 1, wherein the system further comprises a controller configured to control the filling cylinder and the adjustable mixing cylinder. The cooperative controller module compares the speed data of the filling cylinder module with the real-time rotating speed value of the adjustable stirring cylinder module in real time. When the filling speed change rate exceeds a preset fluctuation threshold, a stirring rotating speed compensation instruction is generated to the adjustable stirring cylinder module.

6. The system of claim 5, wherein the controller is configured to control the filling cylinder and the adjustable mixing cylinder based on the measured pressure of the fluid in the filling cylinder. The cooperative controller module divides a filling process into three cooperative control window periods, namely a preparation stage, a main filling stage and a supplementary filling stage. Each cooperative control window period corresponds to a mapping relationship of different filling cylinder displacement parameters and adjustable stirring cylinder rotating speed parameters.

7. The system of claim 6, wherein the controller is configured to control the filling cylinder and the adjustable mixing cylinder based on the measured pressure of the fluid in the filling cylinder. In the supplementary filling stage window period, the weighing measurement module starts a weight change continuous monitoring mode. The cooperative controller module dynamically switches the high-speed mode and the slow-speed mode of the filling cylinder according to the weight change continuous monitoring data.

8. The system of claim 1, wherein the system further comprises a controller configured to control the filling cylinder and the adjustable mixing cylinder. The cooperative controller module generates a cooperative effect evaluation parameter based on the error rate of the final filling liquid level value and the target liquid level value, the total filling compensation value execution result and the stirring rotating speed matching degree. The cooperative effect evaluation parameter is used to update the historical data record set of the SPC data analysis unit.

9. The system of claim 8, wherein the controller is configured to control the filling cylinder and the adjustable mixing cylinder based on the measured pressure of the fluid in the filling cylinder. ​ ​ 10. The system of claim 9, wherein the controller is configured to control the filling cylinder and the adjustable mixing cylinder based on the measured pressure of the fluid in the filling cylinder. ​ ​

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