Intelligent sensor-based hot-melt slag regenerative rock wool board production control system

Abstract

This invention relates to the field of rock wool board production technology, and more particularly to a production control system for hot-melt slag recycled rock wool boards based on intelligent sensors. The system includes: a light source array; a data acquisition module comprising an image sensor and a thickness sensor; and a production control module comprising: a surface density determination unit for determining whether the surface density distribution of the cotton blank is uniform based on surface density distribution characterization values, and determining whether the surface density of the cotton blank is qualified based on surface density characterization values; a correction unit for determining whether to correct the surface density of abnormal locations based on compensation area; a pendulum control unit for adjusting the overlap of the cotton blank based on characterization differences, and adjusting the linear velocity of the pendulum device based on a preset area; and a curing furnace control unit for determining whether the thickness stability of the rock wool board is qualified based on thickness fluctuation characterization values, thereby adjusting the chain plate spacing of the curing furnace or optimizing the preset distribution characterization values. This invention improves the thickness stability of rock wool boards.

Description

Technical Field

[0001] This invention relates to the field of rock wool board production technology, and in particular to a production control system for hot-melt slag recycled rock wool boards based on intelligent sensors. Background Technology

[0002] Mineral wool products are widely used in industries such as thermal insulation, noise reduction, and fireproofing. Depending on the application requirements, the products are available in different thicknesses. Thickness is a key quality indicator that is a national standard and a concern for customers during the production process. The hot-melt slag-based mineral wool industry is an environmentally friendly industry that utilizes the sensible heat energy of hot-melt slag to produce inorganic fiber cotton. The key processes are hot-melt slag smelting and tempering, high-speed centrifugal fiber production, and high-temperature curing into boards. The spacing between the stacked cotton blanks during high-temperature curing directly affects the thickness of the finished product. Due to frequent fluctuations in the amount of cotton fibers produced during the high-speed centrifugal fiber production process, the weighing surface density of the cotton blanks fluctuates. Cotton blanks with different weighing surface densities exhibit different thickness rebounds after high-temperature curing, and changes in the weighing surface density of the cotton blanks cause fluctuations in the thickness of the finished product.

[0003] Currently, the production line for producing mineral rock wool from hot molten slag uses a method of manually controlling the product thickness, which seriously affects the pass rate of mineral rock wool products: During continuous production, the surface density of the cotton blank fluctuates. When the surface density of the cotton blank increases, the rebound of the finished product increases after high-temperature curing. When the surface density of the cotton blank decreases, the rebound of the finished product decreases after high-temperature curing. The change in rebound caused by the surface density of the cotton blank cannot be matched by manual adjustment, resulting in a large deviation in the thickness of the mineral rock wool products.

[0004] Chinese Patent Application Publication No. CN104909555A discloses a hot-melt slag recycled rock wool and its production method. The hot-melt slag recycled rock wool is suitable for use as a thermal insulation material for industrial equipment and pipelines, thermal equipment, thermal pipelines, and for building interior and exterior wall insulation, sound insulation, and noise reduction. Hot slag at 1400-1450℃, generated from the residual heat of molten slag in an ironmaking furnace, is fed into a high-temperature resistance furnace via a hot slag trough. Yellow sand or silica is added to adjust the acidity coefficient (MK1.4-1.8) and the viscosity of the molten slag. Alternatively, a small resistance furnace can be added to melt the yellow sand or silica and fluxing materials first, and then the mixture of yellow sand or silica and fluxing materials is added to the molten slag in the high-temperature resistance furnace for homogenization, improving the fiber formation of the molten slag. Nitrogen is added to further agitate and homogenize the various materials in the molten slag. The prepared molten liquid is then fed into a high-speed centrifuge via a high-temperature resistant slide plate for high-speed centrifugal spinning. After slag removal, the molten slag recycled rock wool is produced and packaged using an automatic baling machine.

[0005] The existing technology also has the following problems: Due to the characteristics of the hot melt slag itself, the amount of infinite rock wool fiber produced by the high-speed centrifugal cotton making process fluctuates frequently, which causes the weighing surface density of the cotton blank to fluctuate. After the cotton blanks with different weighing surface densities are cured at high temperature, the rebound amount of the product thickness is different, which ultimately leads to poor thickness stability of the rock wool board. Summary of the Invention

[0006] To address this issue, the present invention provides a production control system for recycled rock wool boards based on intelligent sensors, which overcomes the problem in the prior art where the amount of inorganic rock wool fibers fluctuates frequently during the high-speed centrifugal cotton-making process due to the inherent characteristics of hot-melt slag, leading to fluctuations in the areal density of the cotton blank and ultimately resulting in poor thickness stability of the rock wool board.

[0007] To achieve the above objectives, the present invention provides a production control system for hot-melt slag recycled rock wool boards based on intelligent sensors, comprising:

[0008] A light source array, which is evenly arranged below the conveyor belt between the cotton collection device and the pendulum device, is used to provide backlighting;

[0009] The data acquisition module includes an image sensor for acquiring several image information of the cotton blank surface and a thickness sensor for acquiring the thickness of the rock wool board.

[0010] A production control module, which is connected to the data acquisition module, includes,

[0011] The areal density determination unit is used to determine areal density distribution characterization value and areal density characterization value based on several of the image information, to determine whether the areal density distribution of the cotton blank is uniform according to the comparison result of the areal density distribution characterization value and the preset distribution characterization value, and to determine whether the areal density of the cotton blank is qualified according to the areal density characterization value under the condition that the areal density distribution of the cotton blank is uniform.

[0012] The correction unit is used to determine the abnormal area of ​​several abnormal locations where the surface density of the cotton fabric is unqualified based on a preset gray value, and to determine whether to correct the surface density of the abnormal location based on the comparison result between the compensation area corresponding to the abnormal location within a preset range and the preset area.

[0013] The pendulum control unit is used to adjust the overlap of the cotton blank based on the difference between the areal density characterization value and the preset characterization value, and to adjust the linear velocity of the pendulum device based on the area difference between the preset area and the compensation area.

[0014] The curing oven control unit is used to determine whether the thickness stability of the rock wool board is qualified based on the thickness fluctuation characterization value of the rock wool board, and to adjust the chain plate spacing of the curing oven or optimize the preset distribution characterization value based on the judgment result that the thickness stability of the rock wool board is not qualified.

[0015] Furthermore, the areal density determination unit divides the surface of the cotton blank into several grid regions based on several image information, determines the gray value of any grid region, determines the standard deviation of several gray values ​​as the areal density distribution characterization value, and determines the arithmetic mean of several gray values ​​as the areal density characterization value.

[0016] Furthermore, the areal density determination unit determines that the areal density distribution of the cotton fabric is uniform based on the comparison result that the areal density distribution characterization value is less than or equal to the preset distribution characterization value;

[0017] The non-uniformity of the surface density distribution of the cotton preform is determined based on the comparison result that the surface density distribution characterization value is greater than the preset distribution characterization value.

[0018] Furthermore, under the condition that the surface density distribution of the cotton blank is uniform, the surface density determination unit determines that the surface density of the cotton blank is unqualified based on the comparison result that the surface density characterization value is less than the first preset characterization value or greater than the second preset characterization value.

[0019] Furthermore, when the pendulum control unit determines that the areal density of the cotton blank is unqualified, it sets several overlap adjustment coefficients based on the comparison result of the first characteristic difference and the first characteristic difference of the areal density characteristic value, so as to increase the overlap based on the several overlap adjustment coefficients.

[0020] Furthermore, when the pendulum control unit determines that the areal density of the cotton blank is unqualified, it sets several overlap correction coefficients based on the comparison result of the second characterization difference between the areal density characterization value and the second preset characterization value and the preset characterization difference, so as to reduce the overlap degree based on the several overlap correction coefficients.

[0021] Furthermore, under the condition that the surface density distribution of the cotton fabric is uneven, the correction unit determines several abnormal locations where the surface density of the cotton fabric is unqualified based on a preset gray value. For a single abnormal location, it determines a compensation area corresponding to the abnormal location within a preset range with the geometric center of the abnormal location as the reference point and a preset distance as the radius. Based on the comparison result that the compensation area is less than a first preset area or greater than a second preset area, it determines the surface density of the abnormal location to be corrected.

[0022] Furthermore, the pendulum control unit, under the condition of determining the surface density to correct the abnormal position, sets several linear velocity adjustment coefficients to adjust the linear velocity based on the comparison result of the first area difference and the preset area difference between the first preset area and the compensation area.

[0023] Based on the comparison result of the second area difference between the compensated area and the second preset area and the preset area difference, several linear velocity correction coefficients are set to adjust the linear velocity.

[0024] Furthermore, the curing oven control unit determines that the thickness stability of the rock wool board is unqualified based on the comparison result that the thickness fluctuation characterization value of the rock wool board is greater than the preset fluctuation characterization value.

[0025] Furthermore, when the thickness stability of the rock wool board is determined to be unqualified, the curing furnace control unit determines to increase the chain plate spacing of the curing furnace by adjusting the spacing coefficient based on the comparison result that the difference between the thickness fluctuation characterization value and the preset fluctuation characterization value is less than or equal to the preset fluctuation characterization value.

[0026] Based on the comparison result that the fluctuation characterization difference is greater than the preset fluctuation characterization difference, the preset distribution characterization value is reduced by the characterization value adjustment coefficient.

[0027] Compared with the prior art, the beneficial effects of this invention are as follows: This invention sets up a light source array below the conveyor belt between the cotton collecting device and the pendulum device to collect image information of the cotton blank on the conveyor belt. The grayscale values ​​of the image information are used to determine whether the surface density and surface density distribution of the cotton blank are qualified. The cotton blank is a loose material formed by the accumulation of fibers on the cotton surface. When the light source below the conveyor belt illuminates the cotton blank, the light undergoes three processes: absorption, scattering, and transmission. In areas with higher surface density, the fibers are more densely packed, and the number of fibers per unit volume is greater. At this time, the probability of light being blocked, absorbed, and scattered by the fibers when passing through the cotton blank is greater, resulting in less light flux reaching the image acquisition device. Less light flux results in a lower grayscale value. Conversely, in areas with lower surface density, the fibers are more loosely packed, resulting in less light blocking and scattering, more light flux passing through, and a higher grayscale value. The surface density distribution characterization value is used to determine whether the surface density distribution of the cotton blank is uniform, and under the condition of uniform surface density distribution, the surface density distribution is further determined. Whether the density is up to standard, the uniformity of the areal density distribution characterizes the local differences in the cotton blank, indicating whether there are areas that are too thick, too thin, or unevenly packed. A satisfactory uniformity means that the fiber packing density difference is small in different parts of the cotton blank, avoiding poor thickness uniformity of the rock wool board due to localized thinness or thickness. However, uniformity only reflects whether each area is consistent, not whether this consistency meets the thickness requirements of the rock wool board. If only uniformity is met but the overall areal density is too low or too high, the overall thickness of the final rock wool board will fluctuate. If only the overall areal density is satisfactory but the distribution is uniform, it may cause localized areas of the cotton blank to be too thin or too thick, leading to localized thickness fluctuations in the final rock wool board. Under the condition of a uniform areal density distribution, the overlap should be reduced for cases of excessive areal density and increased for cases of excessive areal density to improve the overall areal density compliance. The uniformity of areal density directly affects the consistency of the rock wool board thickness, thereby further improving the thickness stability of the rock wool board.

[0028] Furthermore, under the condition of uneven surface density distribution, the present invention determines the location of unqualified surface density based on gray value, and determines whether further correction is needed based on the area of ​​the compensation location within a preset range. The cotton blank needs to undergo heating and softening, adhesive curing, and shaping processes in the curing machine. During the heating stage, the adhesive between fibers in the cotton blank will soften and even exhibit a certain degree of fluidity. At the same time, the fibers themselves may become more easily deformed at high temperatures. At this time, if there is a thickness deviation in a local area of ​​the cotton blank, the area will generate higher internal pressure or gravitational potential energy due to material accumulation, flowing to the surrounding thinner areas. Therefore, the present invention first determines the location of excessive thinness or excessive thickness based on gray value, and then verifies whether there is an excessively thick or thin location within a preset range for the determined location. If there is no corresponding location or the area of ​​the corresponding location is insufficient to compensate for the surface density difference of the abnormal location, the linear velocity of the pendulum device at the corresponding location is adjusted to increase or decrease the degree of cotton blank accumulation, thereby improving the overall surface density uniformity of the cotton blank and further improving the thickness stability of the rock wool board.

[0029] Furthermore, the present invention determines whether the stability of the rock wool board is qualified based on the thickness fluctuation characterization value of the rock wool board, and adjusts the chain plate spacing of the curing furnace or optimizes the preset uniformity characterization value for unqualified cases, so as to further improve the uniformity of the overall surface density of the cotton blank and further improve the thickness stability of the rock wool board. Attached Figure Description

[0030] Figure 1 This is a structural block diagram of the hot-melt slag recycled rock wool board production control system based on intelligent sensors, according to an embodiment of the present invention.

[0031] Figure 2 A flowchart for determining whether the areal density distribution of cotton preform is uniform in an embodiment of the present invention;

[0032] Figure 3 A flowchart for determining whether the areal density of cotton preform is qualified according to an embodiment of the present invention;

[0033] Figure 4 This is a flowchart for determining whether the thickness stability of rock wool boards is qualified in an embodiment of the present invention. Detailed Implementation

[0034] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0035] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0036] It should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0037] Please see Figures 1-4 As shown, Figure 1 This is a structural block diagram of a production control system for hot-melt slag recycled rock wool boards based on intelligent sensors. Figure 2 A flowchart for determining whether the areal density distribution of cotton preform is uniform in an embodiment of the present invention; Figure 3 A flowchart for determining whether the areal density of cotton preform is qualified according to an embodiment of the present invention; Figure 4 This is a flowchart for determining whether the thickness stability of rock wool boards is qualified in an embodiment of the present invention.

[0038] This invention provides a production control system for recycled rock wool boards made from hot-melt slag based on intelligent sensors, comprising:

[0039] A light source array, which is evenly arranged below the conveyor belt between the cotton collection device and the pendulum device, is used to provide backlighting;

[0040] The data acquisition module includes an image sensor mounted above the conveyor belt to acquire image information of the surface of the cotton blank, and a thickness sensor to acquire the thickness of the rock wool board.

[0041] A production control module, which is connected to the data acquisition module, includes,

[0042] The areal density determination unit is used to determine areal density distribution characterization value and areal density characterization value based on several of the image information, to determine whether the areal density distribution of the cotton blank is uniform according to the comparison result of the areal density distribution characterization value and the preset distribution characterization value, and to determine whether the areal density of the cotton blank is qualified according to the areal density characterization value under the condition that the areal density distribution of the cotton blank is uniform.

[0043] The correction unit is used to determine the abnormal area of ​​several abnormal locations where the surface density of the cotton fabric is unqualified based on a preset gray value, and to determine whether to correct the surface density of the abnormal location based on the comparison result between the compensation area corresponding to the abnormal location within a preset range and the preset area.

[0044] The pendulum control unit is used to adjust the overlap of the cotton blank based on the difference between the areal density characterization value and the preset characterization value, and to adjust the linear velocity of the pendulum device based on the area difference between the preset area and the compensation area.

[0045] The curing oven control unit is used to determine whether the thickness stability of the rock wool board is qualified based on the thickness fluctuation characterization value of the rock wool board, and to adjust the chain plate spacing of the curing oven or optimize the preset distribution characterization value based on the judgment result that the thickness stability of the rock wool board is not qualified.

[0046] Understandably, the process of generating rock wool boards using hot-melt slag includes: using a centrifugal method to draw the high-temperature melt formed by hot-melt slag into rock wool fibers; using a cotton collecting device to lay the rock wool fibers onto a conveyor belt to form a cotton blank; the cotton blank is conveyed to a pendulum device via a conveyor belt; the cotton blank is spread out by the left and right swing of the pendulum to form an initial cotton blank; and the initial cotton blank is cured in a curing furnace at high temperature to form a rock wool board.

[0047] Specifically, the light source of the light source array can be an LED strip light source or a surface light source, and the spectrum can be selected as full spectrum or near-infrared spectrum, without being specifically limited, and is evenly distributed below the conveyor belt.

[0048] Specifically, the image sensor may be, for example, the ams Osram Mira series, and is not specifically limited, as long as it meets the shooting requirements; the thickness sensor may be, for example, an infrared thickness sensor or the Thermo Fisher PROSIS™ series, and is not specifically limited, as long as it meets the thickness measurement requirements.

[0049] Specifically, the areal density determination unit divides the surface of the cotton blank into several grid regions based on several image information, determines the gray value of any grid region, determines the standard deviation of several gray values ​​as the areal density distribution characterization value, and determines the arithmetic mean of several gray values ​​as the areal density characterization value.

[0050] Specifically, the division of the grid area is not limited. Those skilled in the art can determine the size of the grid according to actual needs. In practice, the surface of the cotton blank can be divided into several grids of 5cm×10cm, and scaled down proportionally to the size of the conveyor belt in the image information according to the ratio of the conveyor belt size in the image information to the actual size of the conveyor belt.

[0051] Specifically, determining the grayscale value of a grid region based on image information requires preprocessing the image information such as noise reduction, correction, and alignment before dividing it into grids. After preprocessing, the image is divided into several grids according to the proportion, and the grayscale value of any grid region is read. This is existing technology and will not be elaborated further.

[0052] Specifically, the areal density determination unit determines that the areal density distribution of the cotton blank is uniform based on the comparison result that the areal density distribution characterization value is less than or equal to the preset distribution characterization value;

[0053] The non-uniformity of the surface density distribution of the cotton preform is determined based on the comparison result that the surface density distribution characterization value is greater than the preset distribution characterization value.

[0054] Specifically, the preset distribution characterization value is determined by selecting the standard deviation of the gray value of at least 50 batches of qualified cotton blanks that have been tested and confirmed to have uniform surface density distribution and thickness that meets the standard after curing. The maximum value among several standard deviations is determined as the preset distribution characterization value. The selectable range of the preset distribution characterization value is set to [12, 25]. The preferred embodiment of the present invention is 20.

[0055] Specifically, the areal density determination unit determines that the areal density of the cotton blank is unqualified based on the comparison result that the areal density characterization value is less than a first preset characterization value or greater than a second preset characterization value, provided that the areal density distribution of the cotton blank is uniform.

[0056] The areal density determination unit determines that the areal density of the cotton blank is qualified based on the comparison result that the areal density characterization value is greater than or equal to the first preset characterization value and less than or equal to the second preset characterization value.

[0057] Specifically, the preset characterization value is determined by selecting the arithmetic mean of the gray values ​​of at least 50 batches of qualified cotton blanks that have been tested and confirmed to have uniform surface density distribution and thickness that meets the standard after curing. 1.1 times the maximum value among several arithmetic means is determined as the second preset characterization value, and 0.9 times the minimum value among several arithmetic means is determined as the first preset characterization value. The selectable range of the first preset characterization value is set to [100, 150], preferably 120 in this embodiment of the invention. The selectable range of the second preset characterization value is set to [200, 230], preferably 200 in this embodiment of the invention.

[0058] Specifically, when the pendulum control unit determines that the surface density of the cotton blank is unqualified, it sets several overlap adjustment coefficients based on the comparison result of the first characteristic difference and the preset characteristic difference of the surface density characteristic value, so as to increase the overlap based on the several overlap adjustment coefficients.

[0059] Specifically, the pendulum control unit determines to increase the overlap by a first overlap adjustment coefficient based on a comparison result that the first characterization difference is greater than the preset characterization difference.

[0060] The pendulum control unit determines to increase the overlap by a second overlap adjustment coefficient based on a comparison result where the first characterization difference is less than or equal to the preset characterization difference.

[0061] Specifically, the preset characterization difference is set to a value range of [30, 50], preferably 40 in this embodiment of the invention; the first overlap adjustment coefficient is set to a value range of [1.3, 1.5], preferably 1.4 in this embodiment of the invention; and the second overlap adjustment coefficient is set to a value range of [1.05, 1.2], preferably 1.1 in this embodiment of the invention.

[0062] Specifically, when the pendulum control unit determines that the surface density of the cotton blank is unqualified, it sets several overlap correction coefficients based on the comparison result of the second characteristic difference between the surface density characterization value and the second preset characterization value and the preset characterization difference, so as to reduce the overlap based on the several overlap correction coefficients.

[0063] Specifically, the pendulum control unit determines to reduce the overlap by using a first overlap correction coefficient based on a comparison result where the second characterization difference is greater than the preset characterization difference.

[0064] The pendulum control unit determines to reduce the overlap by using a second overlap correction coefficient based on a comparison result where the second characterization difference is less than or equal to the preset characterization difference.

[0065] It is understood that the overlap refers to the percentage of the length of the overlapping area between the cotton fiber layers laid in adjacent swing cycles to the lateral distance of the cotton blank during the process of the pendulum device laying cotton blank.

[0066] Specifically, the first overlap correction coefficient is set to a value range of [0.8, 0.9], and preferably 0.85 in this embodiment of the invention. The second overlap correction coefficient is set to a value range of [0.91, 0.95], and preferably 0.92 in this embodiment of the invention.

[0067] Specifically, under the condition that the surface density distribution of the cotton blank is uneven, the correction unit determines several abnormal locations where the surface density of the cotton blank is unqualified based on a preset gray value. For a single abnormal location, it determines a compensation area corresponding to the abnormal location within a preset range with the geometric center of the abnormal location as the reference point and a preset distance as the radius. Based on the comparison result that the compensation area is less than a first preset area or greater than a second preset area, it determines the surface density of the abnormal location to be corrected.

[0068] Based on the comparison result that the compensation area is greater than or equal to the first preset area and less than or equal to the second preset area, it is determined that the surface density of the abnormal position will not be corrected.

[0069] Specifically, based on preset gray values, abnormal locations where the surface density of the cotton blank is too low or too high are determined. The range of preset gray values ​​is the range formed by the first preset characterization value and the second preset characterization value, i.e., [120, 200]. If the gray value of the cotton blank surface is less than 120, it indicates that the surface density of the cotton blank at that location is too high. If the gray value of the cotton blank surface is greater than 200, it indicates that the surface density of the cotton blank at that location is too low. For abnormal locations where the surface density of the cotton blank is too low, a compensation area with a gray value less than 120 is determined within a preset range formed with the geometric center of the abnormal location as the reference point and a preset distance as the radius. For abnormal locations where the surface density of the cotton blank is too high, a compensation area with a gray value greater than 200 is determined within a preset range formed with the geometric center of the abnormal location as the reference point and a preset distance as the radius.

[0070] Understandably, abnormal locations indicate areas where the areal density of the cotton fabric is too low or too high. The abnormal area of ​​an abnormal location is the area formed by connecting pixel blocks with gray values ​​less than 120 or greater than 200. The compensation area is the area within a preset range that has the opposite areal density state to the abnormal area. If the abnormal area is the area with a lower areal density of the cotton fabric, then the compensation area is the area with a higher areal density of the cotton fabric within the preset range; if the abnormal area is the area with a higher areal density of the cotton fabric, then the compensation area is the area with a lower areal density of the cotton fabric within the preset range.

[0071] It is understandable that when the cotton blank is cured in the curing furnace, the rock wool fibers have fluidity within a small range. If there are both areas with low areal density and areas with high areal density within the flow range of the rock wool fibers, the fluidity of the rock wool fibers can complement each other to make the thickness of the final rock wool board meet the standard.

[0072] Specifically, the preset range is the flow range of rock wool fibers in the curing oven. It is a range formed with the geometric center of the abnormal area at the abnormal location as the reference and a preset distance as the radius. The value of the preset distance is determined according to the temperature of the curing oven. For example, if the temperature range of the curing oven is 180℃-210℃, the preset distance is [10cm, 15cm]; if the temperature range of the curing oven is 250℃-400℃, the preset distance is [20cm, 30cm]. In practice, the preferred value in this embodiment of the invention is 15cm.

[0073] Specifically, the pendulum control unit, under the condition of determining the surface density to correct the abnormal position, sets several linear velocity adjustment coefficients to adjust the linear velocity based on the comparison result of the first area difference and the preset area difference between the first preset area and the compensation area.

[0074] Based on the comparison result of the second area difference between the compensated area and the second preset area and the preset area difference, several linear velocity correction coefficients are set to adjust the linear velocity.

[0075] Specifically, the first preset area and the second preset area are determined according to the following formulas: First preset area = Grayscale deviation × Abnormal area × Scale coefficient + Minimum base area; Second preset area = Grayscale deviation × Abnormal area × Scale coefficient + Maximum base area. Here, grayscale deviation is the difference between the grayscale value at the abnormal location and either the first or second preset characteristic value. If the surface density at the abnormal location is low, then grayscale deviation = grayscale value at the abnormal location - second preset characteristic value; if the surface density at the abnormal location is high, then grayscale deviation = first preset characteristic value - grayscale value at the abnormal location. The scale coefficient is 0.02, and the minimum base area is 10 mm². 2 The maximum base area is 30mm². 2 .

[0076] Specifically, when the surface density at the abnormal location is determined to be less than a first preset characterization value, the pendulum control unit determines to increase the linear velocity by a first linear velocity adjustment coefficient based on a comparison result that the first area difference is greater than the preset area difference.

[0077] Based on the comparison result that the first area difference is less than or equal to the preset area difference, the linear velocity is increased by a second linear velocity adjustment coefficient.

[0078] Specifically, the preset area difference range is set to [15mm]. 2 20mm 2 In this embodiment of the invention, 18mm is preferred. 2 The first linear velocity adjustment coefficient is set to a value range of [1.08, 1.13], preferably 1.1 in this embodiment of the invention. The second linear velocity adjustment coefficient is set to a value range of [1.03, 1.07], preferably 1.05 in this embodiment of the invention.

[0079] Specifically, when the pendulum control unit determines that the surface density at the abnormal position is greater than the second preset characterization value, it determines to reduce the linear velocity by a first linear velocity correction coefficient based on the comparison result that the second area difference is greater than the preset area difference.

[0080] Based on the comparison result that the second area difference is less than or equal to the preset area difference, the linear velocity is reduced by a second linear velocity correction coefficient.

[0081] Specifically, the range of the first linear velocity correction coefficient is set to [0.81, 0.84], and 0.82 is preferred in this embodiment of the invention. The range of the second linear velocity correction coefficient is set to [0.85, 0.91], and 0.88 is preferred in this embodiment of the invention.

[0082] Specifically, when the pendulum control unit determines that the surface density at the abnormal position is less than the first preset characterization value, it determines to reduce the linear velocity by a third linear velocity correction coefficient based on the comparison result that the second area difference is greater than the preset area difference.

[0083] Based on the comparison result that the second area difference is less than or equal to the preset area difference, the linear velocity is reduced by a fourth linear velocity correction coefficient.

[0084] Specifically, the value range of the third linear velocity correction coefficient is set to [0.86, 0.89], and 0.87 is preferred in this embodiment of the invention. The value range of the fourth linear velocity correction coefficient is set to [0.9, 0.93], and 0.91 is preferred in this embodiment of the invention.

[0085] Specifically, when the pendulum control unit determines that the surface density at the abnormal position is greater than the second preset characterization value, it determines to increase the linear velocity by a third linear velocity adjustment coefficient based on the comparison result that the first area difference is greater than the preset area difference.

[0086] Based on the comparison result that the first area difference is less than or equal to the preset area difference, the linear velocity is increased by the fourth linear velocity adjustment coefficient.

[0087] Specifically, the value range of the third linear velocity adjustment coefficient is set to [1.06, 1.11], and preferably 1.07 in this embodiment of the invention; the value range of the fourth linear velocity adjustment coefficient is set to [1.02, 1.05], and preferably 1.03 in this embodiment of the invention.

[0088] Specifically, the curing oven control unit determines that the thickness stability of the rock wool board is unqualified based on the comparison result that the thickness fluctuation characterization value of the rock wool board is greater than the preset fluctuation characterization value.

[0089] The thickness stability of the rock wool board is determined to be qualified based on the comparison result that the thickness fluctuation characterization value of the rock wool board is less than or equal to the preset fluctuation characterization value.

[0090] Specifically, the thickness fluctuation characterization value refers to the standard deviation of the thickness at different locations of the rock wool board. The preset fluctuation characterization value is selected from the mode of the standard deviation of the thickness of at least 50 batches of qualified rock wool boards whose thickness has been tested and confirmed to meet the standard. The selectable range of the preset fluctuation characterization value is set to [3mm, 7mm]. In this embodiment of the invention, 5mm is preferred.

[0091] Specifically, when the thickness stability of the rock wool board is determined to be unqualified, the curing furnace control unit determines to increase the chain plate spacing of the curing furnace by adjusting the spacing coefficient based on the comparison result that the difference between the thickness fluctuation characterization value and the preset fluctuation characterization value is less than or equal to the preset fluctuation characterization value.

[0092] Based on the comparison result that the fluctuation characterization difference is greater than the preset fluctuation characterization difference, the preset distribution characterization value is reduced by the characterization value adjustment coefficient.

[0093] Specifically, the preset fluctuation characterization difference range is set to [1mm, 4mm], preferably 3mm in this embodiment of the invention; the spacing adjustment coefficient range is set to [1.12, 1.17], preferably 1.15 in this embodiment of the invention; and the characterization value adjustment coefficient range is set to [0.92, 0.97], preferably 0.94 in this embodiment of the invention.

[0094] Specifically, rock wool boards are conveyed and cured in a curing furnace via chain conveyors. The chain conveyor spacing is one of the key parameters affecting the thickness uniformity of the rock wool board. The chain conveyor spacing directly determines the supporting pressure on the rock wool board during the curing process: the smaller the spacing, the stronger the compression / supporting effect of the chain conveyor on the rock wool board, and the local thickness may become thinner due to uneven pressure; the larger the spacing, the gentler the pressure of the chain conveyor on the rock wool board, and the more sufficient the space for fiber flow and filling in local areas, making it easier to compensate for local thickness deviations through the natural flow of fibers. When the fluctuation characteristic difference is small, the uniformity of supporting pressure can be optimized by appropriately increasing the chain conveyor spacing, thereby reducing local thickness deviations. When the fluctuation characteristic difference is large, it is necessary to reduce the preset distribution characteristic value to improve the judgment standard for the uniformity of the areal density distribution of the cotton blank, fundamentally reducing the thickness fluctuation of the rock wool board.

[0095] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A production control system for recycled rock wool boards made from hot-melt slag based on intelligent sensors, characterized in that, include: A light source array, which is evenly arranged below the conveyor belt between the cotton collection device and the pendulum device, is used to provide backlighting; The data acquisition module includes an image sensor for acquiring several image information of the cotton blank surface and a thickness sensor for acquiring the thickness of the rock wool board. The production control module is connected to the data acquisition module. include, The areal density determination unit is used to determine areal density distribution characterization value and areal density characterization value based on several of the image information, to determine whether the areal density distribution of the cotton blank is uniform according to the comparison result of the areal density distribution characterization value and the preset distribution characterization value, and to determine whether the areal density of the cotton blank is qualified according to the areal density characterization value under the condition that the areal density distribution of the cotton blank is uniform. The correction unit is used to determine the abnormal area of ​​several abnormal locations where the surface density of the cotton fabric is unqualified based on a preset gray value, and to determine whether to correct the surface density of the abnormal location based on the comparison result between the compensation area corresponding to the abnormal location within a preset range and the preset area. The pendulum control unit is used to adjust the overlap of the cotton blank based on the difference between the areal density characterization value and the preset characterization value, and to adjust the linear velocity of the pendulum device based on the area difference between the preset area and the compensation area. The curing oven control unit is used to determine whether the thickness stability of the rock wool board is qualified based on the thickness fluctuation characterization value of the rock wool board, and to adjust the chain plate spacing of the curing oven or optimize the preset distribution characterization value based on the judgment result that the thickness stability of the rock wool board is not qualified.

2. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 1, characterized in that, The areal density determination unit divides the surface of the cotton blank into several grid regions based on several image information, determines the gray value of any grid region, determines the standard deviation of several gray values ​​as the areal density distribution characterization value, and determines the arithmetic mean of several gray values ​​as the areal density characterization value.

3. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 2, characterized in that, The areal density determination unit determines that the areal density distribution of the cotton blank is uniform based on the comparison result that the areal density distribution characterization value is less than or equal to the preset distribution characterization value; Based on the comparison results of the areal density distribution characterization value being greater than the preset distribution characterization value, it is determined that the areal density distribution of the cotton blank is uneven.

4. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 3, characterized in that, The areal density determination unit determines that the areal density of the cotton blank is unqualified based on the comparison result that the areal density characterization value is less than a first preset characterization value or greater than a second preset characterization value, provided that the areal density distribution of the cotton blank is uniform.

5. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 4, characterized in that, When the pendulum control unit determines that the surface density of the cotton blank is unqualified, it sets several overlap adjustment coefficients based on the comparison result of the first characteristic difference and the first characteristic difference of the surface density characteristic value and the preset characteristic difference, so as to increase the overlap based on the several overlap adjustment coefficients.

6. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 4, characterized in that, When the pendulum control unit determines that the surface density of the cotton blank is unqualified, it sets several overlap correction coefficients based on the comparison result of the second characteristic difference between the surface density characterization value and the second preset characterization value and the preset characterization difference, so as to reduce the overlap degree based on the several overlap correction coefficients.

7. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 3, characterized in that, Under the condition that the surface density distribution of the cotton blank is uneven, the correction unit determines a number of abnormal locations where the surface density of the cotton blank is unqualified based on a preset gray value. For a single abnormal location, it determines a compensation area corresponding to the abnormal location within a preset range with the geometric center of the abnormal location as the reference point and a preset distance as the radius. Based on the comparison result that the compensation area is less than a first preset area or greater than a second preset area, it determines the surface density of the abnormal location to be corrected.

8. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 7, characterized in that, The pendulum control unit, under the condition of determining the surface density to correct the abnormal position, sets several linear velocity adjustment coefficients to adjust the linear velocity based on the comparison result of the first area difference and the preset area difference between the first preset area and the compensation area. Based on the comparison result of the second area difference between the compensated area and the second preset area and the preset area difference, several linear velocity correction coefficients are set to adjust the linear velocity.

9. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 8, characterized in that, The curing oven control unit determines that the thickness stability of the rock wool board is unqualified based on the comparison result that the thickness fluctuation characterization value of the rock wool board is greater than the preset fluctuation characterization value.

10. The production control system for hot-melt slag recycled rock wool board based on intelligent sensors according to claim 9, characterized in that, When the thickness stability of the rock wool board is determined to be unqualified, the control unit of the curing furnace determines to increase the chain plate spacing of the curing furnace by adjusting the spacing coefficient based on the comparison result that the difference between the thickness fluctuation characterization value and the preset fluctuation characterization value is less than or equal to the preset fluctuation characterization value. Based on the comparison result that the fluctuation characterization difference is greater than the preset fluctuation characterization difference, the preset distribution characterization value is reduced by the characterization value adjustment coefficient.

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