Intelligent asynchronous repasting system and method

Abstract

The invention relates to an intelligent asynchronous transfer pasting system and method, and relates to the technical field of die cutting machining.The intelligent asynchronous transfer pasting system comprises a rack, an A material conveying mechanism, a B material conveying mechanism, a transfer pasting mechanism and a finished product conveying mechanism are installed on the rack, the transfer pasting mechanism comprises a first machine base, and a first steel roller, a first concave roller, a scraper and a limiting roller are installed on the first machine base; a channel for the material A and the material B to pass through is arranged between the scraper and the limiting roller; the A material conveying mechanism is used for driving a material A to pass through the space between the first intelligent asynchronous roller and the first steel roller, the scraper, the first steel roller and the first concave roller in sequence and then be sent out; the B material conveying mechanism is used for driving a B material to sequentially pass through a channel between the scraper and the limiting roller and between the steel roller and the concave roller and then be sent out; the device further comprises a detection mechanism which is in signal connection with a control module, and the end of the control module is in signal connection with the signal input ends of the A material conveying mechanism and the B material conveying mechanism. According to the invention, the precision of sheet transferring and pasting processing can be guaranteed.

Description

Technical Field

[0001] This application relates to the field of die-cutting technology, and in particular to an intelligent asynchronous transfer system and method. Background Technology

[0002] Die-cutting machines, also known as cutting machines, are mainly used for die-cutting, hot stamping, and bonding of various non-metallic materials, self-adhesive labels, EVA, double-sided tape, electronic and mobile phone pads, etc. In the die-cutting production process, it is often necessary to bond two graphic materials together. Ordinary asynchronous transfer die-cutting machines control the bonding position of the patterns on material A and material B by controlling the jump distance between the patterns.

[0003] A common asynchronous transfer die-cutting system mainly includes a frame, on which are installed an A-material traction mechanism, a B-material traction mechanism, and a transfer mechanism. During the transfer process, the A-material traction mechanism pulls and conveys the A-material to the transfer mechanism, and the B-material traction mechanism pulls and conveys the B-material to the transfer mechanism. The transfer mechanism usually consists of a scraper and a limiting roller. The limiting roller is located directly below the scraper, and a slit is formed between the scraper and the limiting roller to allow the A-material and B-material to pass through. The A-material is conveyed through the scraper, and the B-material is conveyed through the limiting roller. By controlling the jump distance of the A-material and B-material, the sheet material on the A-material is pasted onto the base material on the B-material.

[0004] However, during the production process, issues such as die-cutting defects and positional deviations may occur. Ordinary asynchronous feeding can only continue to feed and bond according to a fixed jump distance, and cannot adjust the jump distance of the base material according to the actual jump distance of the sheet material, making it difficult to ensure production quality control. Summary of the Invention

[0005] To improve the accuracy of sheet transfer position control and ensure product quality control, this application provides an intelligent asynchronous transfer system and method.

[0006] The intelligent asynchronous reposting system and method provided in this application adopts the following technical solution: An intelligent asynchronous transfer system and method includes a frame on which an A-material conveying mechanism, a B-material conveying mechanism, a transfer mechanism, and a finished product conveying mechanism are installed. The transfer mechanism includes a first base on which a first intelligent asynchronous roller, a first steel roller, and a first concave roller are installed sequentially from top to bottom. A scraper and a limiting roller are also installed on the first base. The scraper is positioned above the limiting roller, and a channel for A-material and B-material to pass through is provided between the scraper and the limiting roller. The material A conveying mechanism is used to drive material A to pass sequentially between the first intelligent asynchronous roller and the first steel roller, through the scraper, and between the first steel roller and the first concave roller before being delivered out. The material B conveying mechanism is used to drive material B through the channel between the scraper and the limiting roller, and between the steel roller and the concave roller in sequence before sending it out. It also includes a detection mechanism for detecting color marks of material A and material B. The signal output terminal of the detection mechanism is connected to a control module, and the signal output terminal of the control module is connected to the signal input terminals of the material A conveying mechanism and the material B conveying mechanism.

[0007] Preferably, the A material conveying mechanism includes an A material unwinding mechanism, a second base, a third base, a fourth base, and a first waste material winding mechanism mounted on a frame. The A material unwinding mechanism, the second base, the third base, and the fourth base are arranged sequentially along the conveying direction of the A material. The second machine base is equipped with a first rubber roller and a second steel roller, with the first rubber roller mounted above the second steel roller; The third machine base is equipped with a circular cutter roller and a third steel roller, with the circular cutter roller positioned above the third steel roller. The fourth machine base is equipped with a fourth steel roller and a second concave roller, with the fourth steel roller mounted above the second concave roller. Material A is sequentially passed between the first rubber roller and the second steel roller, between the circular cutter roller and the third steel roller, between the fourth steel roller and the second concave roller, and between the first steel roller and the first concave roller before being discharged; The first waste material winding mechanism is mounted above the A material unwinding mechanism, the second machine base, the third machine base, and the fourth machine base, and the first waste material winding mechanism is located at the discharge end of the circular cutter roller. The first waste material winding mechanism is used to wind up the waste material formed after cutting the A material.

[0008] Preferably, an infrared correction mechanism is installed on the frame, and the infrared correction mechanism is located between the A material unwinding mechanism and the second machine base; The frame is equipped with a first traction roller and a second traction roller. The first traction roller and the second traction roller are located on the feed side and the discharge side of the infrared correction mechanism, respectively, and the height of the first traction roller and the second traction roller is lower than that of the infrared correction mechanism.

[0009] Preferably, the B material conveying mechanism includes a B material unwinding mechanism, a first intelligent asynchronous roller, a second intelligent asynchronous roller, and a second waste material winding mechanism. The B material unwinding mechanism and the second waste material winding mechanism are mounted above the first machine base, the second machine base, the third machine base, and the fourth machine base, and the second waste material winding mechanism is located between the first waste material winding mechanism and the B material unwinding mechanism. The first intelligent asynchronous roller is mounted on the first machine base and is positioned above the first steel roller; the second intelligent asynchronous roller is mounted on the fourth machine base and is positioned above the fourth steel roller. The B material unwinding mechanism is used to transport the B material sequentially between the second intelligent asynchronous roller and the fourth steel roller, between the first intelligent asynchronous roller and the first steel roller, between the scraper and the limiting roller, between the first steel roller and the first concave roller, and between the fourth steel roller and the second concave roller, and then it is wound up by the second waste material winding mechanism.

[0010] Preferably, a separating rod is installed on the frame, the separating rod is located between the first steel roller and the fourth steel roller, and the height of the separating rod is higher than that of the first steel roller and the fourth steel roller.

[0011] Preferably, the finished product conveying mechanism includes a finished product winding mechanism and a fifth base. The fifth base is located on the side of the first base away from the fourth base, and the finished product winding mechanism is mounted above the fifth base and located on the side of the fifth base away from the first base. The fifth machine base is equipped with a second rubber roller and a fifth steel roller. The finished product winding mechanism drives the finished product to pass between the second rubber roller and the fifth steel roller and then winds it up.

[0012] Preferably, the detection mechanism includes a first color mark sensor and a second color mark sensor. The first color mark sensor is fixedly installed on the first base and mounted above the scraper, and the second color mark sensor is fixedly installed on the fifth base and mounted above the limiting roller.

[0013] Preferably, the signal output terminals of the first color mark sensor and the second color mark sensor are respectively connected to a signal processing module. The signal processing module includes a signal quality assessment unit, a performance trend analysis unit, and a fault diagnosis unit. The signal output terminals of the quality assessment unit, the performance trend analysis unit, and the fault diagnosis unit are all connected to the display on the control panel.

[0014] An asynchronous intelligent reposting method includes the following steps: Step S1, Pre-operation debugging: Before the equipment is operated, the first color mark sensor and the second color mark sensor are debugged to ensure that the first color mark sensor and the second color mark sensor are functioning normally; Step S2, Parameter Settings: Set the transfer speed, transfer length, waiting distance, sensor restricted area length, and correction limit length in sequence; Among them, the transfer speed is the length of the finished product output per minute; the transfer length is the length of the sheet material; after the second color mark sensor detects the color mark next to the bottom material and the conveying distance reaches the waiting distance, the first intelligent asynchronous roller and the second intelligent asynchronous roller start to convey the sheet material through the scraper; the sensing restricted area is determined based on the distance between two adjacent bottom material color marks on material A; the correction limit length is the maximum error of the original spacing between two adjacent sheet materials on material B. Step S3: Set the induction asynchronous switch to ON and the transfer function switch to ON. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of Embodiment 1 of this application, used to illustrate the overall structure of the intelligent asynchronous transfer system.

[0016] Figure 2 yes Figure 1 The enlarged diagram at point A in the middle is mainly used to show the installation positions of the first color mark sensor and the second color mark sensor.

[0017] Figure 3 This is a schematic diagram of Embodiment 1 of this application used to illustrate the positional relationship between waste material B and material A.

[0018] Figure 4 This is a schematic diagram of the signal transmission of the signal processing module in Embodiment 2 of this application.

[0019] Explanation of reference numerals in the attached drawings: 1. Frame; 11. Separating rod; 2. Material A conveying mechanism; 21. Material A unwinding mechanism; 22. Second machine base; 221. First rubber roller; 222. Second steel roller; 23. Third machine base; 231. Circular cutter roller; 232. Third steel roller; 24. Fourth machine base; 241. Fourth steel roller; 242. Second concave roller; 25. First waste material winding mechanism; 26. Infrared correction mechanism; 3. Material B conveying mechanism; 31. Material B unwinding mechanism; 32, first intelligent asynchronous roller; 33, second intelligent asynchronous roller; 34, second waste material winding mechanism; 4, transfer mechanism; 41, first machine base; 42, first steel roller; 43, first concave roller; 44, scraper; 45, limit roller; 5, finished product conveying mechanism; 51, finished product winding mechanism; 52, fifth machine base; 521, second rubber roller; 522, fifth steel roller; 7, first color mark sensor; 8, second color mark sensor. Detailed Implementation

[0020] The following combination Figures 1-4 This application will be described in further detail.

[0021] Example 1 This application discloses an intelligent asynchronous transfer system and method. (Refer to...) Figures 1-3 It mainly includes a frame 1, on which an A material conveying mechanism 2, a B material conveying mechanism 3, a transfer mechanism 4, and a finished product conveying mechanism 5 are installed.

[0022] In this process, the sheet material is located on material A, and the base material is located on material B. Material A conveying mechanism 2 and material B conveying mechanism 3 respectively convey material A and material B through transfer mechanism 4. Transfer mechanism 4 transfers the sheet material on material A to the base material on material B to form a finished product. Finished product conveying mechanism 5 can wind the finished product into a roll.

[0023] To ensure the accuracy of the transfer position between the sheet material and the base material, in this embodiment, a detection mechanism is also installed on the frame 1. The detection mechanism is used to detect the color mark next to the sheet material on material A and the color mark next to the base material on material B. The signal output terminal of the detection mechanism is connected to the signal input terminal of the controller through a data cable. The signal output terminal of the control mechanism is connected to the signal input terminals of the material A conveying mechanism 2 and the material B conveying mechanism 3 through a data cable.

[0024] The color marks on material A and material B are tested by the testing agency. The control module can adjust the rhythm of material A conveying mechanism 2 and material B conveying mechanism 3 according to the test results of the color marks next to the sheet material and the base material, so as to ensure that the sheet material is accurately transferred to the base material.

[0025] Please refer to Figure 1 and Figure 2 The transfer mechanism 4 includes a first base 41, on which a first steel roller 42, a first concave roller 43, a scraper 44, and a limiting roller 45 are mounted. The first steel roller 42 is positioned above the first concave roller 43. The scraper 44 is located on the discharge side of the first steel roller 42, and the limiting roller 45 is located below the scraper 44. A channel for material A and material B to pass through is provided between the scraper 44 and the limiting roller 45. The two ends of the limiting roller 45 are fixed by two support arms mounted on the first base 41.

[0026] Material A conveying mechanism 2 includes a material A unwinding mechanism 21, a second base 22, a third base 23, a fourth base 24 and a first waste material winding mechanism 25 mounted on the frame 1. The material A unwinding mechanism 21, the second base 22, the third base 23 and the fourth base 24 are arranged sequentially along the conveying direction of material A.

[0027] The second machine base 22 is equipped with a first rubber roller 221 and a second steel roller 222, with the first rubber roller 221 positioned above the second steel roller 222; the third machine base 1 is equipped with a circular cutter roller 231 and a third steel roller 232, with the circular cutter roller 231 positioned above the third steel roller 232; the fourth machine base 24 is equipped with a fourth steel roller 241 and a second concave roller 242, with the fourth steel roller 241 positioned above the second concave roller 242.

[0028] The first waste winding mechanism 25 is mounted above the second base 22, the third base 23 and the fourth base 24, and the first waste winding mechanism 25 is located on the side of the second base 22 away from the third base 23.

[0029] The height of the A material unwinding mechanism 21 is lower than that of the second machine base 22, the third machine base 23 and the fourth machine base 24. After being unwound by the A material unwinding mechanism 21, the A material passes sequentially between the first rubber roller 221 and the second steel roller 222, between the circular knife roller 231 and the third steel roller 232, between the fourth steel roller 241 and the second concave roller 242, between the first steel roller 42 and the first concave roller 43, and between the scraper 44 and the limiting roller 45 before being sent out.

[0030] It should be noted that in this embodiment, material A is divided into an upper layer and a lower layer. The sheet material is printed on the upper layer according to a set spacing, and the upper layer is bonded to the lower layer by adhesive. When material A passes between the circular cutter roller 231 and the third steel roller 232, the circular cutter roller 231 cuts the upper layer material, cutting the base material on the upper layer material into individual pieces. The base material formed after cutting the upper layer material is still bonded to the surface of the lower layer material. The waste material generated after cutting the upper layer material is wound and recycled by the first waste material winding mechanism 25.

[0031] To ensure the conveying accuracy of material A, in this embodiment, an infrared correction mechanism 26, a first traction roller, and a second traction roller are also installed on the frame 1. The infrared correction mechanism 26 is located between the material A unwinding mechanism 21 and the second base 22. The first traction roller is located on the feeding side of the infrared correction mechanism 26, and the second traction roller is located on the discharging side of the infrared correction mechanism 26. The heights of the first traction roller and the second traction roller are both lower than the infrared correction mechanism 26. The first traction roller and the second traction roller can ensure that material A maintains a certain tension as it passes through the infrared correction mechanism 26.

[0032] Reference Figure 1 The B-material conveying mechanism 3 includes a B-material unwinding mechanism, a first intelligent asynchronous roller 32, a second intelligent asynchronous roller 33, and a second waste material winding mechanism 34. The first intelligent asynchronous roller 32 is mounted on the first machine base 41 and is positioned directly above the first steel roller 42; the second intelligent asynchronous roller 33 is mounted on the fourth machine base 24 and is positioned directly above the fourth steel roller 241; the first intelligent asynchronous roller 32 and the second intelligent asynchronous roller 33 are driven by drive mechanisms mounted on the first machine base 41 and the fourth machine base 24, respectively.

[0033] The B material unwinding mechanism 31 and the second waste material winding mechanism 34 are both located above the second machine base 22, the third machine base 23, and the fourth machine base 24, with the second waste material winding mechanism 34 located between the first waste material winding mechanism 25 and the B material unwinding mechanism 31. The B material output by the B material unwinding mechanism 31 passes sequentially between the second intelligent asynchronous roller 33 and the fourth steel roller 241, between the first intelligent asynchronous roller 32 and the first steel roller 42, between the scraper 44 and the limiting roller 45, between the first steel roller 42 and the first concave roller 43, and between the fourth steel roller 241 and the second concave roller 242 before being recycled by the second waste material winding mechanism 34.

[0034] It should be noted that the sheet material is pre-cut into individual pieces and adhered to the surface of material B. As material B passes through the blade of scraper 44, the leading portion of the sheet material on material B separates from the underlying material and curls up. After the sheet material on material A passes below scraper 44, the curled-up head adheres to the surface of the base material that is continuously fed forward below the scraper. After the sheet material is attached to the base material surface, material A and material B are synchronously driven to continuously feed the finished roll material, which is then conveyed out by the subsequent finished product conveyor mechanism 5.

[0035] Reference Figure 1 In this embodiment of the application, a separating rod 11 is fixedly installed on the frame 1. The separating rod 11 is located between the first machine base 41 and the fourth machine base 24, and the height of the separating rod 11 is higher than the top roller surface of the first concave roller 43 and the second concave roller 242.

[0036] Reference Figure 3 In the actual production and processing process, the separating rod 11 supports the waste material of material B, so that the waste material of material B is in close contact with the bottom roller surface of the first steel roller 42 and the fourth steel roller 241, so as to ensure that the waste material of material B and material A passing through the top roller surface of the second concave roller 242 and the first concave roller maintain a certain distance, and prevent the waste material of material B from sticking to material A.

[0037] The finished product conveying mechanism 5 includes a fifth base 52 mounted on the frame 1 and a finished product winding mechanism 51. The fifth base 52 is located on the side of the first base 41 away from the fourth base 24, and the finished product winding mechanism 51 is located above the fifth base 52 and on the side of the fifth base 52 away from the first base 41.

[0038] A second rubber roller 521 and a fifth steel roller 522 are mounted on the fifth base 52. The second rubber roller 521 is positioned above the fifth steel roller 522. The finished product formed by transferring the sheet material from material B to the base material on material A passes between the second rubber roller 521 and the fifth steel roller 522 and is then wound into a roll by the finished product winding mechanism 51. The first rubber roller 221 and the second rubber roller 521 are driven by drive mechanisms mounted on the second base 22 and the fifth base 52, respectively.

[0039] Please refer to Figure 2The detection mechanism includes a first color mark sensor 7 and a second color mark sensor 8. The first color mark sensor 7 is fixedly installed on a crossbar on the first base 41 and is positioned directly above the scraper 44 near the blade edge. The second color mark sensor 8 is fixedly installed on a crossbar on the fifth base 52 and is positioned directly above the limiting roller 45.

[0040] The synchronous rotation of the first rubber roller 221 and the second rubber roller 521 can drive material A to move according to the set jump distance, so that the bottom material of material A passes between the scraper 44 and the limiting roller 45 in sequence; the synchronous rotation of the first intelligent asynchronous roller 32 and the second intelligent asynchronous roller 33 can drive material B to move between the scraper 44 and the limiting roller 45.

[0041] During the transfer process, the A material conveying mechanism 2 conveys the base material sequentially between the scraper 44 and the limiting roller 45 according to the jump distance of the base material and the given conveying speed, while the B material conveying mechanism 3 conveys the sheet material through the transfer mechanism 4 according to the jump distance of the sheet material and the given conveying speed.

[0042] The signal input terminal of the control module is connected to the signal output terminals of the first color mark sensor 7, the second color mark sensor 8, and the human-machine interface control panel of the console. Before the transfer process, the operator can set the transfer speed, transfer length, waiting distance, sensing exclusion zone length, and correction limit length through the human-machine interface control panel of the console. Based on the set transfer speed, transfer length, waiting distance, sensing exclusion zone length, and correction limit length, the control module, in conjunction with the sensing signals output by the first color mark sensor 7 and the second color mark sensor 8, controls the A material conveying mechanism 2 and the B material conveying mechanism 3 to perform asynchronous transfer processing.

[0043] When the sheet material jump distance is abnormal, the time interval of the sensing signal measured by the first color mark sensor 7 is abnormal. The control module controls the A material conveying mechanism 2 to stop conveying A material until the color mark next to the next sheet material of B material passes the first color mark sensor 7. At the same time, during the subsequent B material conveying process, the jump distance of the sheet material can be obtained by automatically detecting the color mark next to the sheet material. The cycle time and conveying frequency of the B material conveying mechanism 3 can be automatically adjusted according to the jump distance of the sheet material, so as to achieve the technical effect of automatically detecting the jump distance and automatically adjusting the transfer cycle time.

[0044] After the sheet material is transferred to the base material, the B material is conveyed between the second rubber roller 521 and the fifth steel roller 522. The second rubber roller 521 rolls the sheet material pasted on the continuously passing sheet material, which can make the sheet material completely adhere to the base material and prevent the sheet material from curling up.

[0045] Based on the aforementioned intelligent asynchronous reposting system, this application also proposes an intelligent asynchronous reposting method, which mainly includes the following steps: Step S1, Pre-operation debugging: Before the equipment is operated, the first color mark sensor and the second color mark sensor are debugged to ensure that the first color mark sensor and the second color mark sensor are functioning normally; Step S2, Parameter Settings: Set the transfer speed, transfer length, waiting distance, sensor restricted area length, and correction limit length in sequence; Among them, the transfer speed is the length of the finished product output per minute; the transfer length is the length of the sheet material; after the second color mark sensor detects the color mark next to the bottom material and the conveying distance reaches the waiting distance, the first intelligent asynchronous roller and the second intelligent asynchronous roller start to convey the sheet material through the scraper; the sensing restricted area is determined based on the distance between two adjacent bottom material color marks on material A; the correction limit length is the maximum error of the original spacing between two adjacent sheet materials on material B. Step S3: Set the induction asynchronous switch to ON and the transfer function switch to ON.

[0046] For example, in this embodiment, the set transfer speed is 5m / min, the transfer length (i.e., the ideal length of the sheet material) is 57mm, and the waiting distance is 34mm. The waiting distance of 34mm is exactly the spacing between the sheets. However, this spacing is not consistent during the actual patching process. The spacing of the first group is 34mm, while the spacing of the next group may be 30mm or 40mm, or other sizes. The sensing exclusion zone length is 80mm (setting a sensing exclusion zone can prevent recognition errors caused by changes in product color), and the correction limit length is 2mm.

[0047] During the transfer process, under normal circumstances, the A material conveying mechanism continuously and sequentially conveys the base material at a set conveying speed, passing under the scraper and the limiting roller. When the second color mark sensor 8 detects the color mark next to the passing sheet material and outputs a sensing signal, the control module controls the A material conveying mechanism to drive the base material to move a waiting distance of 34mm (the purpose of this waiting distance is to ensure that the sheet material is 34mm behind the color mark of the base material; in some other embodiments, this can be adjusted according to actual production needs). Then, the B material conveying mechanism is controlled to drive the B material to move. After the sheet material on the B material passes the blade of the scraper, it separates from the B material and is attached to the base material.

[0048] When a sheet of material B is missing or misaligned, the interval between the sensing signals output by the first color mark sensor 7 becomes abnormal. The control module stops the material A conveying mechanism, but the material B conveying mechanism continues to feed until the next normal sheet of material B reaches a position below the first color mark sensor 7, and the first color mark sensor 7 detects a color mark next to the new sheet. At this point, the control module stops the material B conveying mechanism. The distance between the previous and next normal sheet of material B is the actual jump distance value, which is generally 34mm, but may be other values ​​in practice. At this time, the control module controls the material A conveying mechanism to continue conveying material A, and the distance of conveying material A is the actual jump distance value measured above. When material A has completed the actual jump distance value of conveying, and the second color mark sensor 8 detects a color mark next to the new base material on material A, the control module controls the material B conveying mechanism to convey material B (while the material A conveying mechanism continues to convey the base material). When material B passes the scraper, the sheet head on material B lifts up and adheres to the base material passing below.

[0049] During the adjustment process, the control module recalculates the jump distance of the sheet material based on the rhythm of the sensing signal output by the first color mark sensor, and automatically adjusts the rhythm of the A material conveying mechanism and the B material conveying mechanism to achieve the technical effect of asynchronous adjustment of the sheet material conveying.

[0050] Example 2 In this embodiment, the signal output terminals of the first color mark sensor and the second color mark sensor are respectively connected to a signal processing module. This signal processing module is used to evaluate the signal quality of the sensing signals output by the first or second color mark sensor, and to evaluate the state of the first or second color mark sensor based on the signal quality. Please refer to... Figure 4 The signal processing module includes a signal quality assessment unit, a performance trend analysis unit, and a fault diagnosis unit.

[0051] The signal quality assessment unit calculates the signal-to-noise ratio (SNR), stability, and contrast consistency based on the received sensing signal, and then calculates the detection quality score of the first or second color mark sensor based on these three parameters. The formula for calculating the detection quality score T is as follows: ; ; In the formula, SNR represents the real-time signal-to-noise ratio of the first color mark sensor or the second color mark sensor; S_t is the stability, which represents the standard deviation of the signal strength when the same color mark is detected in the last 20 times; C is the contrast consistency, which represents the ratio of the real-time signal-to-noise ratio to the historical standard signal-to-noise ratio of the color mark stored in the dynamic baseline database; V_L and V_B represent the signal strength of the first color mark sensor (or the second color mark sensor) when passing through the color mark and the background; S_N represents the standard deviation of the readings when continuously reading the background area in a short period of time; α, β, and γ are the weights of the real-time signal-to-noise ratio, stability, and contrast consistency, respectively, and α+β+γ=1.

[0052] In actual production, the signal quality assessment unit can calculate the detection quality score for each detection action of the first color mark sensor or the second color mark sensor. If the detection quality score T is lower than the set threshold, it is determined that the first color mark sensor or the second color mark sensor is in an abnormal state, and an alarm signal is displayed on the display to prompt the monitoring personnel to maintain the first color mark sensor or the second color mark sensor in a timely manner.

[0053] The dynamic baseline database stores parameters of the first and second color mark sensors under healthy conditions. These parameters include standard signal-to-noise ratio (SNR), signal range, environmental parameters, and historical trend data. The standard SNR is the baseline value measured under optimal conditions and continuously and smoothly updated. The signal range represents the maximum and minimum normal readings of the color mark or background detected by either the first or second color mark sensor. Environmental parameters include ambient temperature and humidity during self-test. The historical trend data consists of the daily real-time average SNR and the daily average stability.

[0054] In this embodiment, under the condition of no alarm and high quality score, the signal-to-noise ratio baseline value is updated by exponential smoothing at a time interval of 10 days to simulate the system adapting to the aging of the first color mark sensor or the second color mark sensor.

[0055] The performance trend and analysis unit operates every set number of times (based on daily production volume) of the first or second color mark sensor to analyze its long-term health trend. Its analysis methods primarily include: extracting the average daily SNR from the dynamic baseline database over the past week; determining the trend of the average daily SNR using a linear regression algorithm model; judging the operating status of the first and second color mark sensors based on the trend of the average daily SNR; and outputting a performance degradation signal if the displayed SNR is continuously decreasing and will fall below the set SNR threshold. This facilitates timely cleaning, replacement, and maintenance of the first or second color mark sensor by operators.

[0056] At the same time, after receiving the performance degradation signal, the fault diagnosis unit obtains the current signal characteristics, environmental data, and historical SNR baseline from the dynamic baseline database. Based on the current signal characteristics, environmental data, and historical SNR baseline, it diagnoses the fault type of the first color mark sensor or the second color mark sensor using a pre-established rule base model, and displays the corresponding fault name and maintenance operation on the display.

[0057] The trained rule base model extracts key and measurable diagnostic indicators for operators in advance, and associates fault modes with fault causes during training. Diagnostic indicators include overall signal level trends, noise levels, SNR trends, and rates of change. In this embodiment, fault modes include light source aging, lens contamination, ambient light interference, mechanical vibration or loose installation, detection distance deviation, and hardware / electrical faults. When building the rule base model, operators can assign a priority to each fault mode based on its historical frequency, and select the highest-priority fault mode for output and display during actual calculations.

[0058] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An intelligent asynchronous transfer system, characterized in that, The machine includes a frame (1), on which an A material conveying mechanism (2), a B material conveying mechanism (3), a transfer mechanism (4), and a finished product conveying mechanism (5) are installed. The transfer mechanism (4) includes a first base (41), on which a first intelligent asynchronous roller (32), a first steel roller (42), and a first concave roller (43) are installed from top to bottom. A scraper (44) and a limiting roller (45) are also installed on the first base (41). The scraper (44) is mounted above the limiting roller (45), and a channel for A material and B material to pass through is provided between the scraper (44) and the limiting roller (45). The material A conveying mechanism (2) is used to drive material A to pass sequentially between the first intelligent asynchronous roller (32) and the first steel roller (42), between the scraper (44), and between the first steel roller (42) and the first concave roller (43) before being sent out; The B material conveying mechanism (3) is used to drive the B material to pass sequentially through the channel between the scraper (44) and the limiting roller (45), and between the steel roller and the concave roller before being sent out; It also includes a detection mechanism for detecting the color mark of material A and the color mark of material B. The signal output terminal of the detection mechanism is connected to a control module, and the signal output terminal of the control module is connected to the signal input terminal of the material A conveying mechanism (2) and the material B conveying mechanism (3).

2. The intelligent asynchronous transfer system according to claim 1, characterized in that, The A material conveying mechanism (2) includes an A material unwinding mechanism (21), a second base (22), a third base (23), a fourth base (24) and a first waste material winding mechanism (25) installed on the frame (1). The A material unwinding mechanism (21), the second base (22), the third base (23) and the fourth base (24) are arranged sequentially along the conveying direction of the A material. The second machine base (22) is equipped with a first rubber roller (221) and a second steel roller (222), with the first rubber roller (221) mounted above the second steel roller (222); The third machine base (23) is equipped with a circular cutter roller (231) and a third steel roller (232), with the circular cutter roller (231) mounted above the third steel roller (232); The fourth base (24) is equipped with a fourth steel roller (241) and a second concave roller (242), with the fourth steel roller (241) mounted above the second concave roller (242); Material A passes sequentially between the first rubber roller (221) and the second steel roller (222), between the circular cutter roller (231) and the third steel roller (232), between the fourth steel roller (241) and the second concave roller (242), and between the first steel roller (42) and the first concave roller (43) before being discharged. The first waste material winding mechanism (25) is mounted above the A material unwinding mechanism (21), the second machine base (22), the third machine base (23) and the fourth machine base (24), and the first waste material winding mechanism (25) is located at the discharge end of the circular cutter roller (231). The first waste material winding mechanism (25) is used to wind up the waste material formed after cutting the A material.

3. The intelligent asynchronous transfer system according to claim 2, characterized in that, An infrared correction mechanism (26) is installed on the frame (1), and the infrared correction mechanism (26) is located between the A material unwinding mechanism (21) and the second base (22); The frame (1) is equipped with a first traction roller and a second traction roller. The first traction roller and the second traction roller are located on the feeding side and the discharging side of the infrared correction mechanism (26), and the height of the first traction roller and the second traction roller is lower than that of the infrared correction mechanism (26).

4. The intelligent asynchronous transfer system according to claim 2, characterized in that, The B material conveying mechanism (3) includes a B material unwinding mechanism, a first intelligent asynchronous roller (32), a second intelligent asynchronous roller (33), and a second waste material winding mechanism (34). The B material unwinding mechanism and the second waste material winding mechanism (34) are mounted above the first machine base (41), the second machine base (22), the third machine base (23), and the fourth machine base (24), and the second waste material winding mechanism (34) is located between the first waste material winding mechanism (25) and the B material unwinding mechanism. The first intelligent asynchronous roller (32) is mounted on the first machine base (41) and is erected above the first steel roller (42). The second intelligent asynchronous roller (33) is mounted on the fourth machine base (24) and is erected above the fourth steel roller (241). The B material unwinding mechanism is used to transport the B material sequentially between the second intelligent asynchronous roller (33) and the fourth steel roller (241), between the first intelligent asynchronous roller (32) and the first steel roller (42), between the scraper (44) and the limiting roller (45), between the first steel roller (42) and the first concave roller (43), and between the fourth steel roller (241) and the second concave roller (242), and then it is wound up by the second waste material winding mechanism (34).

5. The asynchronous intelligent transfer system according to claim 4, characterized in that, A separation rod (11) is installed on the frame (1). The separation rod (11) is located between the first steel roller (42) and the fourth steel roller (241), and the height of the separation rod (11) is higher than that of the first steel roller (42) and the fourth steel roller (241).

6. The asynchronous intelligent transfer system according to claim 5, characterized in that, The finished product conveying mechanism (5) includes a finished product winding mechanism (51) and a fifth base (52). The fifth base (52) is located on the side of the first base (41) away from the fourth base (24). The finished product winding mechanism (51) is mounted above the fifth base (52) and is located on the side of the fifth base (52) away from the first base (41). The fifth machine base (52) is equipped with a second rubber roller (521) and a fifth steel roller (522). The finished product winding mechanism (51) drives the finished product to pass between the second rubber roller (521) and the fifth steel roller (522) and then winds it up.

7. An asynchronous intelligent transfer system according to claim 6, characterized in that, The detection mechanism includes a first color mark sensor (7) and a second color mark sensor (8). The first color mark sensor (7) is fixedly installed on the first base (41) and mounted above the scraper (44). The second color mark sensor (8) is fixedly installed on the fifth base (52) and mounted above the limiting roller (45).

8. An asynchronous intelligent transfer system according to claim 7, characterized in that, The control module receives the sensing signals output by the first color mark sensor (7) and the second color mark sensor (8) and controls the A material conveying mechanism (2) and the B material conveying mechanism (3) according to the input transfer speed, transfer length, waiting distance, sensing restricted area length and correction limit length.

9. An asynchronous intelligent transfer system according to claim 8, characterized in that, The signal output terminals of the first color mark sensor (7) and the second color mark sensor (8) are respectively connected to a signal processing module. The signal processing module includes a signal quality evaluation unit, a performance trend analysis unit, and a fault diagnosis unit. The signal output terminals of the quality evaluation unit, the performance trend analysis unit, and the fault diagnosis unit are all connected to the display on the control panel.

10. An asynchronous intelligent reposting method according to claims 1-9, characterized in that, Includes the following steps: Step S1, Pre-operation debugging: Before the equipment is operated, the first color mark sensor and the second color mark sensor are debugged to ensure that the first color mark sensor and the second color mark sensor are functioning normally; Step S2, Parameter Settings: Set the transfer speed, transfer length, waiting distance, sensor restricted area length, and correction limit length in sequence; Among them, the transfer speed is the length of the finished product output per minute; the transfer length is the length of the sheet material; after the second color mark sensor detects the color mark next to the bottom material and the conveying distance reaches the waiting distance, the first intelligent asynchronous roller and the second intelligent asynchronous roller start to convey the sheet material through the scraper; the sensing restricted area is determined based on the distance between two adjacent color marks next to the bottom material on material A; The correction limit length is the maximum error of the original spacing between two adjacent sheets on material B; Step S3: Set the induction asynchronous switch to ON and the transfer function switch to ON.

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