Temperature and speed joint control based a-grade fireproof core material intelligent production line

Abstract

The application discloses a kind of A-grade fireproof core material intelligent production line based on temperature-speed joint control, including raw material mixing conveying system, non-woven cloth attachment and first stripping system, multi-parameter joint control system, cooling and secondary stripping system.Non-woven cloth attachment and first stripping system, including non-woven cloth attachment mechanism and first stripping mechanism, multi-parameter joint control system, by moisture content control system and baking system composition.In line, non-woven cloth attachment, first stripping, cooling and secondary stripping mechanism are added, and according to the temperature sensor array, microwave sensor array detection each hot air circulation oven temperature, different position core material moisture content value, the temperature of baking system and the transmission speed of conveyor belt are synergistically intelligently regulated, while infrared thermal imager is additionally provided, and hot air circulation oven function temperature zone is controlled in partition.Compared with prior art, the application realizes production line speed improvement and greatly reduces the rate of defective products by deep integration of Internet of Things, big data and the like.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, specifically to an intelligent production line for Class A fire-resistant core materials based on temperature-speed joint control. It is particularly suitable for the efficient production of fire-resistant aluminum composite panel core materials for high-rise buildings, and can significantly improve the fire resistance, flexibility and production efficiency of the core materials. Background Technology

[0002] In recent years, frequent fires in high-rise buildings have placed unprecedented demands on the fire safety of building decoration materials. Traditional aluminum composite panels (PE core, Class B fire retardant) pose significant safety hazards under extreme conditions. Class A fire-retardant aluminum composite panels, with their superior flame-retardant properties of inorganic core materials, have become a much-needed alternative in the market. However, their core production technology has long been monopolized by German and Japanese giants, who hold over 85% of the global market share. The key to breaking through this predicament lies in embracing intelligent manufacturing and achieving a fundamental transformation of the production model.

[0003] The core pain points in the current production of Class A fire-resistant aluminum composite panels profoundly reflect the limitations of traditional manufacturing models, urgently requiring comprehensive intelligent empowerment. The foreign-dominated molding process relies on manual intervention and frequent mold changes, resulting in low production line speeds (only about 1.5m / min), low efficiency, and high costs, lacking flexible and continuous intelligent production process support. While there has been progress domestically, product performance (such as total calorific value of 1.8MJ / kg) still lags behind top-tier levels (such as the target of 0.7MJ / kg in this project), and insufficient intelligentization prevents the realization of product winding and transportation, greatly limiting its application scope. Simultaneously, the inherent brittleness, easy deformation and foaming, poor thickness uniformity (error ±0.3mm), and low yield (less than 90%) of inorganic core materials stem from the lack of real-time accurate perception and intelligent closed-loop control of key parameters such as temperature, tension, and material mixing during the production process, failing to effectively suppress defect generation. In addition, traditional processes rely on high amounts of adhesives (total calorific value of organic matter ≥3.0MJ / kg), making it difficult to meet the most stringent A1 grade standard. Furthermore, the production process lacks intelligent resource optimization and waste recycling management mechanisms, resulting in high energy consumption, heavy pollution, and high overall costs.

[0004] To overcome the technological bottlenecks facing China—optimization of inorganic core material formulations, continuous molding, and the localization of complete sets of equipment—intelligent manufacturing is the only way forward. Solving the problem of poor compatibility between inorganic powders and polymer materials (leading to high water absorption, weak water resistance, and insufficient peel strength) requires building material design and performance prediction models based on big data and artificial intelligence to achieve intelligent iteration of formulations. Overcoming the obstacles to continuous production hinges on developing intelligent complete sets of equipment integrating high-precision sensors, intelligent control systems (temperature, tension, rheology, etc.), and adaptive adjustment mechanisms to achieve online intelligent monitoring and elimination of air bubbles within the core material and real-time intelligent control of surface flatness. To reduce dependence on expensive imported equipment and lower energy consumption and maintenance costs, it is necessary to build a domestically produced intelligent production management platform with self-sensing, self-decision-making, and self-optimization capabilities to achieve intelligent optimization of energy consumption, predictive maintenance, and maximize the benefits of large-scale production.

[0005] In summary, the shortcomings of existing Class A inorganic fire-resistant core materials in terms of production efficiency, product quality, cost control, and environmental friendliness stem from a lack of intelligent technology integration. To meet the urgent demand for high-performance fire-resistant materials in the construction industry, intelligent manufacturing must be established as a core strategy. Only by deeply integrating advanced technologies such as the Internet of Things, big data, and artificial intelligence with manufacturing processes, and constructing a full-chain intelligent manufacturing system covering material design, precise production process control, and intelligent equipment operation and maintenance, can we ultimately achieve efficient, stable, flexible, green, and scalable production of Class A fire-resistant aluminum composite panels. Summary of the Invention

[0006] Purpose of the invention: In view of the problems mentioned in the background art, such as core material cracking due to temperature fluctuations, blistering caused by mismatch between linear speed and temperature control, and structural damage due to thermal stress accumulation in the continuous production of Class A fireproof core materials, the present invention provides an intelligent production line for Class A fireproof core materials based on temperature-speed joint control.

[0007] Technical solution: This invention discloses an intelligent production line for Class A fire-resistant core materials based on temperature-speed joint control, comprising:

[0008] The raw material mixing and conveying system initially mixes and fully stirs inorganic powder and adhesive in a certain proportion, and then conveys them to the conveyor belt through a funnel pipe.

[0009] A nonwoven fabric bonding and primary peeling system includes a nonwoven fabric bonding mechanism and a primary peeling mechanism. The nonwoven fabric bonding mechanism includes first, second, third, and fourth unwinding mechanisms located on both sides of a conveyor belt. The first and second unwinding mechanisms simultaneously release a single layer of nonwoven fabric from the starting end of the conveyor belt, forming a double-layer nonwoven fabric below the core material located above the conveyor belt, supporting the slurry extruded through a funnel pipe. The third and fourth unwinding mechanisms simultaneously release a single layer of nonwoven fabric above the conveyor belt to press and cover the slurry, forming a double-layer nonwoven fabric above the core material. The primary peeling mechanism includes first and second winding mechanisms located in the conveyor belt process of the raw material mixing and conveying system, used to peel off the outer nonwoven fabric on the upper surface and the outer nonwoven fabric on the lower surface of the core material after being extruded by a single-roll mill.

[0010] The multi-parameter joint control system consists of a moisture content control system and a baking system. The baking system includes several hot air circulating ovens arranged between the conveyor belts of the raw material mixing and conveying system. Temperature sensors are arranged at the inlet / outlet of each oven section, forming a temperature sensor array. The moisture content control system includes a moisture content detection device, a control execution mechanism, and a decision-making mechanism. The moisture content detection device includes a microwave sensor array arranged between the several hot air circulating ovens. The control execution mechanism is equipped with a transmission speed controller and an oven temperature control unit. The decision-making mechanism is equipped with an edge computing controller, which, based on the temperature and moisture content values ​​detected by the temperature sensor array and the microwave sensor array, performs coordinated intelligent regulation of the transmission speed of the raw material mixing and conveying system and the temperature of the baking system through the transmission speed controller and the oven temperature control unit.

[0011] The cooling and secondary peeling system includes a cooling pool located between several hot air circulating ovens, third and fourth winding mechanisms, a first twin-roll mill, and a core material winding mechanism. After being baked in several hot air circulating ovens, the core material enters the cooling pool for cooling. The third and fourth winding mechanisms then peel off the inner nonwoven fabric on the upper surface and the inner nonwoven fabric on the lower surface of the core material, respectively. After passing through several hot air circulating ovens again, the core material passes through the twin-roll mill and the core material winding mechanism in sequence.

[0012] Furthermore, the raw material mixing and conveying system puts inorganic powder and glue into the feeder in a certain proportion for preliminary mixing, and then conveys them to the mixing tank through the closed feeder. In the mixing tank, the inorganic powder and glue are fully stirred to make a fireproof slurry, which is then conveyed to the conveyor belt through the funnel pipe.

[0013] Furthermore, the nonwoven fabric bonding mechanism also includes a first fixed wheel, a second fixed wheel, and a mixing box. The first unwinding mechanism, the second unwinding mechanism, the third unwinding mechanism, and the fourth unwinding mechanism are respectively arranged on both sides of the mixing box. The mixing box is connected to the mixing tank, and its lower end is connected to the funnel pipe. The first fixed wheel is arranged between the conveyor belts below the funnel pipe and near the third unwinding mechanism and the fourth unwinding mechanism, and the surface of the first fixed wheel is flush with the surface of the conveyor belt. The second fixed wheel is rotatably arranged directly above the first fixed wheel. The nonwoven fabric released by the first unwinding mechanism and the second unwinding mechanism extends along the conveyor belt conveying direction. The nonwoven fabric released by the third unwinding mechanism and the fourth unwinding mechanism passes around the second fixed wheel and is in the same direction as the conveyor belt conveying direction. All four layers of nonwoven fabric pass between the first fixed wheel and the second fixed wheel and are conveyed along the conveyor belt direction, pressed and covered with slurry to form a double-layer nonwoven fabric wrapping structure for the core material.

[0014] Furthermore, the first winding mechanism is located above the rear conveyor belt of the single-roll mill, the first hot air circulating oven is located between the first winding mechanism and the second winding mechanism, and the second winding mechanism is located below the conveyor belt after the first hot air circulating oven. First, the first winding mechanism peels off the outer layer of nonwoven fabric on the upper surface and sends it into the first hot air circulating oven for heating. Then, the second winding mechanism located below the conveyor belt peels off the outer layer of nonwoven fabric on the lower surface, thus completing the first stage of nonwoven fabric peeling process.

[0015] Furthermore, the baking system comprises 11 hot air circulating ovens, with the second to sixth hot air circulating ovens arranged sequentially, and the seventh to eleventh hot air circulating ovens arranged sequentially. The second to sixth hot air circulating ovens and the seventh to eleventh hot air circulating ovens are connected by conveyor belts. A cooling pool and third and fourth winding mechanisms are provided between the sixth and seventh hot air circulating ovens. A first rolling mill is provided between the fifth and sixth hot air circulating ovens, a second rolling mill is provided between the seventh and eighth hot air circulating ovens, and a second double-roll rolling mill is provided between the eighth and ninth hot air circulating ovens.

[0016] Furthermore, the cooling pool is equipped with heating rods and heat exchangers, and the water temperature is monitored in real time by a temperature sensor. The surface of the cooling pool is also equipped with a first drive wheel, a second drive wheel, and a third drive wheel, which form a certain angle with each other. The core material wrapped with nonwoven fabric is transported through the first drive wheel, the second drive wheel, and the third drive wheel and then through the conveyor belt after the cooling pool. The third and fourth winding mechanisms are respectively set above and below the conveyor belt to wind up the inner nonwoven fabric on the upper surface and the inner nonwoven fabric on the lower surface of the peeled core material.

[0017] Furthermore, the microwave sensor array is deployed at the inlet of the first hot air circulating oven, the outlet of the third hot air circulating oven, the outlet of the sixth hot air circulating oven, the inlet of the seventh hot air circulating oven, and the outlet of the eleventh hot air circulating oven. Infrared thermal imagers are added at the inlet of the first hot air circulating oven, the outlet of the third hot air circulating oven, the outlet of the sixth hot air circulating oven, the outlet of the eleventh hot air circulating oven, and the core material winding mechanism. The inlet of the first hot air circulating oven monitors the initial temperature of the slurry, the outlet of the third hot air circulating oven detects the initial curing temperature, the outlet of the sixth hot air circulating oven records the pre-cooling temperature, the outlet of the eleventh hot air circulating oven collects the final curing temperature, and the core material winding mechanism detects the residual thermal stress of the core material before winding.

[0018] Furthermore, the 11 hot air circulating ovens are divided into the following functional temperature zones and temperature tolerances are defined:

[0019] The first and second hot air circulating ovens are in the rapid rise zone: target temperature difference ≤35℃, fluctuation ±5℃;

[0020] The third to seventh hot air circulating ovens are in the constant temperature zone: target temperature difference ≤15℃, fluctuation ±3℃;

[0021] The eighth and ninth hot air circulating ovens are slow-fall zones: target temperature difference ≤20℃, fluctuation ±4℃;

[0022] The tenth and eleventh hot air circulating ovens are in the rapid temperature drop zone: target temperature difference ≤25℃, fluctuation ±5℃;

[0023] The three-parameter linkage control method of moisture content, temperature, and velocity is as follows:

[0024] Moisture content-driven speed regulation: When the moisture content at the inlet of the first hot air circulating oven is greater than the preset ideal value, the conveyor belt speed is reduced and the temperature of the rapid rise zone is increased;

[0025] Temperature deviation compensation: If the measured temperature in the constant temperature zone is lower than the set value, the conveyor belt speed will be reduced synchronously.

[0026] Thermal stress coordination: If the temperature difference between adjacent hot air circulating ovens is greater than 20°C, increase the temperature of the downstream hot air circulating oven and reduce the conveyor belt speed.

[0027] Cooling closed loop: For every 1°C deviation in the cooling pool temperature, the conveyor belt speed is compensated by 0.1 m / min in the reverse direction.

[0028] Furthermore, based on the temperature and moisture content values ​​detected by the temperature sensor array and microwave sensor array, the edge computing controller performs coordinated intelligent regulation of the transmission speed of the raw material mixing and conveying system and the temperature of the baking system through the transmission speed controller and the oven temperature control unit. Specifically, a dual PID cross-coupling control method is proposed, which dynamically allocates the control weights of speed and temperature through the moisture content error. The outer loop controller V(t) and the inner loop controller Tn(t) influence each other through coupling variables, which are defined as follows:

[0029] e(t) = W target -W(t)

[0030]

[0031] In the formula, W target Let W(t) be the target moisture content, W(t) be the actual moisture content, e(t) be the overall moisture content deviation, and T be the total moisture content deviation. n The current temperature of the nth hot air circulating oven. ΔT is the reference temperature of the nth hot air circulating oven. avg This represents the average temperature deviation of the hot air circulating oven.

[0032] The coupling equation between the conveyor belt speed and the temperature of the hot air circulating oven is:

[0033]

[0034]

[0035] In the formula, α is the coupling coefficient of temperature to velocity, β is the coupling coefficient of velocity to temperature, and e n (t) represents the moisture content deviation at the inlet of the nth hot air circulating oven. W represents the target moisture content at the inlet of the nth hot air circulating oven. n (t) represents the actual moisture content at the inlet of the nth hot air circulating oven, K p1 K i1 K d1 K p2 K i2 K d2 These are the parameters for a dual PID controller;

[0036] Coupling mechanism: The outer loop output speed correction and the inner loop output temperature correction are fed back to each other through a weighting coefficient γ, forming coordinated control, and generating the final command as follows:

[0037] u final =γ·V(t)+(1-γ)·T n (t)

[0038] The weighting coefficient γ is dynamically adjusted based on the moisture content deviation.

[0039] When |e(t)|>2%, γ→1, the system prioritizes suppressing moisture content deviation by adjusting the transmission speed;

[0040] When |e(t)| < 0.8%, γ → 0, the system prioritizes fine compensation by adjusting the temperature;

[0041] When 0.8% < |e(t)| < 2%, The inner loop of the system fine-tunes the temperature, while the outer loop maintains a stable speed.

[0042] Furthermore, when the edge computing controller uses the dual PID cross-coupling control method for coordinated regulation, it also has dynamic limiting protection, specifically:

[0043] Emergency stop threshold, global moisture content deviation: |e(t)|>5%;

[0044] Acceleration safety constraint, velocity mutation rate: |dV / dt| ≤ 0.5 m / min 2 ;

[0045] Thermal stress safety constraints, temperature difference between adjacent hot air circulating ovens: |T (n+1) -T n ≤25℃.

[0046] Beneficial effects:

[0047] 1. This invention achieves precise layering of nonwoven fabric through four sets of independent unwinding mechanisms, ensuring tight adhesion between the sizing agent and the nonwoven fabric. In the nonwoven fabric peeling stage, peeling is performed in two stages. The first peeling is conducted before and after the first hot air circulating oven, peeling off the upper outer layer and the lower outer layer of nonwoven fabric respectively. In the second peeling, the adhesive layer is softened by constant-temperature immersion in a cooling pool, allowing for precise peeling. This achieves efficient nonwoven fabric peeling with zero damage to the core material surface. Furthermore, this invention involves peeling the second layer after the first stage of hot air circulating oven baking, preventing the nonwoven fabric from completely adhering to the core material before the second stage of hot air circulating oven baking.

[0048] 2. The present invention designs a multi-parameter joint control system. First, the temperature of the hot air circulating oven inlet and outlet can be collected in real time through a temperature sensor array. The required moisture content of the hot air circulating oven inlet and outlet can be collected in real time through a microwave sensor array. Based on the required temperature and moisture content values, the conveyor belt speed and the temperature of the baking system can be adjusted in real time to achieve coordinated intelligent control of the conveyor speed and the temperature of the baking system.

[0049] 3. This invention employs a dual-PID cross-coupling control method to intelligently regulate the transmission speed and the temperature of the baking system. It constructs dynamic coupling coefficients and weighting coefficients, with the outer loop output (speed correction) and inner loop output (temperature correction) feeding back to each other through the weighting coefficient γ. The speed and temperature weighting coefficients designed in this invention are dynamically adjusted according to the moisture content deviation, achieving a coordinated response between the two. Furthermore, dynamic limiting protection is also set up on this control basis to further constrain the process of the dual-PID cross-coupling control method.

[0050] 4. This invention also controls temperature and moisture content using multiple parameters. By dividing the 11 functional temperature zones of the hot air circulating oven into zones, different temperature tolerances are set for different zones. Based on different target temperature differences and fluctuation limits, the entire control process is divided into a moisture content-driven speed regulation process, a temperature deviation compensation process, a thermal stress coordination process, and a cooling closed-loop process. Different control methods are set for different processes, which is more suitable for the production needs of Class A fireproof core materials.

[0051] In summary, this invention achieves a moisture content control accuracy of ±0.7% (compared to the traditional ±2.5%). Combined with multi-point temperature control and four-zone temperature management, the core material foaming rate is ≤2.5%, and the thermal stress cracking rate is <0.8%. Dynamic speed regulation (1.5-8.0 m / min) and gradient temperature control work together to reduce drying energy consumption to 180 kWh / ton (from 280 kWh / ton), and increase production line speed to 8 m / min (compared to the traditional 1.5 m / min). Five-point moisture content monitoring and five-infrared thermal imaging provide real-time feedback, with an anomaly response time ≤3 seconds, a yield rate ≥98.5%, and an annual production capacity of 5 million square meters. Attached Figure Description

[0052] Figure 1 This is a schematic diagram of a complete set of equipment for the continuous production process of Class A inorganic fireproof core material provided by the present invention;

[0053] Figure 2 This is a schematic diagram of the nonwoven fabric bonding mechanism for double-layer nonwoven fabric;

[0054] Figure 3 This is a schematic diagram of the cooling and secondary stripping system;

[0055] Figure 4 It is a flowchart of multi-parameter linkage control;

[0056] Figure 5 It is a production line flowchart.

[0057] In the diagram: 101, load-bearing base; 102, first unwinding mechanism; 103, second unwinding mechanism; 104, mixing tank support column; 105, conveyor belt support column; 106, inlet temperature sensor of the first hot air circulating oven; 107, first hot air circulating oven; 108, outlet temperature sensor of the first hot air circulating oven; 109, second winding mechanism; 110, inlet temperature sensor of the second hot air circulating oven; 111, outlet temperature sensor of the sixth hot air circulating oven; 112, cooling pool; 113. Fourth winding mechanism; 114. Seventh hot air circulating oven inlet temperature sensor; 115. Eleventh hot air circulating oven outlet temperature sensor; 116. Infrared thermal imager 5; 117. Core material winding mechanism; 118. First twin-roll mill; 119. Eleventh hot air circulating oven outlet microwave moisture content sensor; 120. Infrared thermal imager 4; 121. Seventh hot air circulating oven inlet microwave moisture content sensor; 122. Third winding mechanism; 123. Sixth hot air circulating oven outlet temperature sensor; 12 4. Infrared thermal imager 3; 125. Conveyor belt; 126. Hot air blower B; 127. Hot air blower A; 128. Infrared thermal imager 1; 129. Microwave moisture content sensor at the inlet of the first hot air circulating oven; 130. First winding mechanism; 131. Single-roll mill; 132. Fourth unwinding mechanism; 133. Third unwinding mechanism; 134. Mixing tank; 135. Feeder; 136. Feeding box; 201. First unwinding roller; 202. Second unwinding roller; 203. First fixed roller; 204. Second fixed roller 205. Fixed reel; 206. Fourth unwinding reel; 207. Third unwinding reel; 208. Funnel pipe; 209. Mixing box; 300. Temperature sensor; 301. Heat exchanger; 302. Motor control system; 303. Conveyor belt support column; 304. Fourth take-up reel; 305. Fourth take-up reel support column; 306. Third take-up reel support column; 317. Third take-up reel; 318. Third drive wheel; 319. Heating rod; 310. Second drive wheel; 311. Fireproof core material; 312. First drive wheel. Detailed Implementation

[0058] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0059] This invention discloses an intelligent production line for Class A fire-resistant core materials based on temperature-speed joint control, such as... Figure 1 It is known that the Class A infinitely variable fire-retardant core material production line includes a raw material mixing and conveying system, a non-woven fabric lamination and primary peeling system, a multi-parameter control system, and a cooling and secondary peeling system. The non-woven fabric lamination and primary peeling system includes a non-woven fabric lamination mechanism and a primary peeling mechanism. The multi-parameter control system consists of a moisture content control system and a baking system.

[0060] The raw material mixing and conveying system includes a load-bearing base 101, one end of which supports a feeding box 136. In the feeding box 136, the inorganic powder and adhesive are mixed and conveyed by a feeder 135 to a mixing tank 134 for thorough mixing. The mixing tank 134 is fixed to the load-bearing base 101 by a mixing tank support column. The feeder 135 can deliver the materials to the mixing tank 134 via a pump or other means. A mixing hopper 208 is located below the mixing tank 134, and a funnel pipe 207 connects to the bottom of the mixing hopper 208. Several conveyor belts 125 are spaced apart above the load-bearing base 101 by conveyor belt support columns 105. Conveyor belts 125 are located below the mixing tank 134, with their starting positions below the funnel pipe 207. Non-woven fabric bonding mechanisms are located on both sides below the funnel pipe 207.

[0061] The nonwoven fabric bonding mechanism includes first, second, third, and fourth unwinding mechanisms 102, 103, 133, and 132 disposed on both sides of the conveyor belt. The first unwinding mechanism 102 and the second unwinding mechanism 103 are respectively the first unwinding wheel 201 and the second unwinding wheel 202. The third unwinding mechanism 133 and the fourth unwinding mechanism 132 are respectively the third unwinding wheel 206 and the fourth unwinding wheel 205. A first fixed wheel 203 and a second fixed wheel 204 are rotatably disposed between the conveyor belt 125 below the funnel pipe 207 and near the third unwinding wheel 206 and the fourth unwinding wheel 205. The first unwinding wheel 201, the second unwinding wheel 202, the third unwinding wheel 206, the fourth unwinding wheel 205, the first fixed wheel 203, and the second fixed wheel 204 can all be driven to rotate by a motor. The first unwinding... Nonwoven fabric rolls are provided on the first unwinding wheel 201, the second unwinding wheel 202, the third unwinding wheel 206, and the fourth unwinding wheel 205. The nonwoven fabric on the first unwinding wheel 201 and the second unwinding wheel 202 extends in the same direction to the conveyor belt 125 and moves forward under the drive of the conveyor belt 125, passing over the upper surface of the first fixed wheel 203. The surface of the first fixed wheel 203 is flush with the surface of the conveyor belt 125. The second fixed wheel 204 is rotatably positioned directly above the first fixed wheel 203. The nonwoven fabric on the third unwinding wheel 206 and the fourth unwinding wheel 205 passes around the second fixed wheel 204 in the same direction and is in the same direction as the conveyor belt 125. The four layers of nonwoven fabric are released synchronously between the first fixed wheel 203 and the second fixed wheel 204 and are pressed together with the covering slurry to form a double-layer nonwoven fabric wrapping structure for the core material.

[0062] The mixing box 208 precisely lays the mixed slurry onto the surface of the lower nonwoven fabric released by the first unwinding roller 201 and the second unwinding roller 202 through the funnel pipe 207. After being transported by the conveyor belt 125, it reaches the positions of the first fixed roller 203 and the second fixed roller 204. The nonwoven fabric of the third unwinding roller 206 and the fourth unwinding roller 205 passes around the second fixed roller 204 in the same direction and presses the mixed slurry on the surface of the lower nonwoven fabric. It continues to be transported forward with the conveyor belt 125 to form a double-layer nonwoven fabric wrapping structure for the core material.

[0063] A single layer of nonwoven fabric is released synchronously from the beginning of the production line and covers the conveyor belt 125, which is supported by the conveyor belt 105 and reinforced. A single roll mill 131 is set after the third unwinding mechanism and the fourth unwinding mechanism. After the upper and lower double layers of nonwoven fabric are bonded to the material, they form the core material and the thickness is adjusted by the single roll mill 131.

[0064] The primary stripping mechanism includes a first winding mechanism 130, which is positioned above the rear conveyor belt 125 of the single-roll mill 131. A first hot air circulating oven 107 is positioned between the first winding mechanism 130 and the second winding mechanism 109. The second winding mechanism 109 is positioned below the conveyor belt 125 following the first hot air circulating oven 107. First, the first winding mechanism 130 strips the outer layer of nonwoven fabric from the upper surface and sends it into the first hot air circulating oven 107 for heating. Then, the second winding mechanism 109, located below the conveyor belt 125, strips the outer layer of nonwoven fabric from the lower surface, completing the first stage of the nonwoven fabric stripping process. In this embodiment, both the first winding mechanism 130 and the second winding mechanism 109 are configured as winding wheel structures, and the winding operation can be driven by a drive motor.

[0065] After the core material is rolled, the top layer of nonwoven fabric is removed by the first winding mechanism 130, and the core material is sent into the first hot air circulating oven 107. The first hot air circulating oven 107 is equipped with hot air blowers A127 and B126. After hot air drying by the linkage of hot air blowers A127 and B126, the core material passes through the second winding mechanism 109 to wind up the bottom outer layer of nonwoven fabric. After drying in the second to sixth hot air circulating ovens, the core material is cooled or surface-treated in the cooling pool 112. The remaining top and bottom layers of nonwoven fabric are then wound up by the third winding mechanism 113 and the fourth winding mechanism 122. After drying in the seventh to eleventh hot air circulating ovens and rolling by the first twin-roll mill 118, the core material is finally wound up by the core material winding mechanism 117.

[0066] On the production line, the baking system includes several hot air circulating ovens arranged between the conveyor belts of the raw material mixing and conveying system. There are 11 hot air circulating ovens, with the second to sixth hot air circulating ovens arranged sequentially, and the seventh to eleventh hot air circulating ovens arranged sequentially. The second to sixth hot air circulating ovens and the seventh to eleventh hot air circulating ovens are connected by conveyor belts 125. A cooling pool 112, a third winding mechanism 133, and a fourth winding mechanism 132 are arranged between the sixth and seventh hot air circulating ovens. A first rolling mill (not shown in the figure) is also arranged between the fifth and sixth hot air circulating ovens. A second rolling mill (not shown in the figure) is arranged between the seventh and eighth hot air circulating ovens. A second double-roll rolling mill (not shown in the figure) is arranged between the eighth and ninth hot air circulating ovens.

[0067] In this embodiment, the temperature control range of the first hot air circulating oven is 280℃~340℃, the temperature control range of the second hot air circulating oven is 250℃~310℃, the temperature control range of the third hot air circulating oven is 170℃~205℃, the temperature control range of the fourth hot air circulating oven is 150℃~185℃, the temperature control range of the fifth hot air circulating oven is 120℃~160℃, the temperature control range of the sixth hot air circulating oven is 145℃~185℃, the temperature control range of the seventh hot air circulating oven is 145℃~185℃, the temperature control range of the eighth hot air circulating oven is 155℃~190℃, the temperature control range of the ninth hot air circulating oven is 155℃~190℃, the temperature control range of the tenth hot air circulating oven is 155℃~190℃, and the temperature control range of the eleventh hot air circulating oven is 210℃~255℃.

[0068] See Figure 3The cooling pool 112 is equipped with heating rods 313 and heat exchangers 304. A temperature sensor 303 monitors the water temperature in real time (control accuracy ±1℃), and a motor control system 305 dynamically adjusts the heating power. The surface of the cooling pool 112 is also equipped with a first drive wheel 316, a second drive wheel 314, and a third drive wheel 312, which form a certain angle to ensure that the core material deforms under pressure and is immersed in the constant-temperature water. The fireproof core material 315 wrapped with non-woven fabric is transported via the first drive wheel 316, the second drive wheel 314, and the third drive wheel 312 through a conveyor belt 125 after the cooling pool 112. A third winding mechanism 133 and a fourth winding mechanism 132 are respectively installed above and below the conveyor belt 125 to wind up the inner non-woven fabric on the upper and lower surfaces of the peeled core material. After soaking, the core material is lifted out of the water by a conveyor belt 310 supported by conveyor belt support columns 306. Simultaneously, the remaining upper and lower layers of nonwoven fabric are peeled off at a preset angle by the third take-up roller 311 and the fourth take-up roller 307 supported by take-up roller support columns 308 and 309. The peeled nonwoven fabric is recycled, and the core material continues to be transported to subsequent processes. This device softens the adhesive layer through constant temperature soaking, combined with precise peeling angle control, to achieve efficient peeling of the nonwoven fabric with zero damage to the core material surface.

[0069] In this embodiment, the third winding mechanism 133 and the fourth winding mechanism 132 are the third winding wheel 311 and the fourth winding wheel 307, respectively, which are fixed to the load-bearing base 101 by the third winding wheel support column 309 and the fourth winding wheel support column 308.

[0070] In the multi-parameter control system, temperature sensors are arranged at the inlet / outlet of each section of the hot air circulating oven, forming a temperature sensor array with a total of 22 monitoring points. These are used to detect the temperature of the core material entering and exiting the oven, thereby adjusting the temperature inside the oven. The moisture content control system includes a moisture content detection device, a control actuator, and a decision-making mechanism. The moisture content detection device includes a microwave sensor array installed between several hot air circulating ovens. The control actuator has a transmission speed controller and an oven temperature control unit. The decision-making mechanism has an edge computing controller, which, based on the temperature and moisture content values ​​detected by the temperature sensor array and the microwave sensor array, coordinates and intelligently regulates the transmission speed of the raw material mixing and conveying system and the temperature of the baking system through the transmission speed controller and the oven temperature control unit.

[0071] The microwave sensor array consists of microwave moisture content sensors, which are deployed at the inlet of the first hot air circulating oven 107, the outlet of the third hot air circulating oven, the outlet of the sixth hot air circulating oven, the inlet of the seventh hot air circulating oven, and the outlet of the eleventh hot air circulating oven. They are located at the upper end of the conveyor belt 125, 10cm vertically from the material surface. The data obtained by the sensors is transmitted to the edge computing controller, which then controls the speed and temperature of the entire production line.

[0072] Furthermore, infrared thermal imagers are added at the inlet of the first hot air circulating oven 107, the outlet of the third hot air circulating oven, the outlet of the sixth hot air circulating oven, the outlet of the eleventh hot air circulating oven, and the core material winding mechanism 117. The inlet of the first hot air circulating oven 107 monitors the initial temperature of the slurry, the outlet of the third hot air circulating oven detects the initial curing temperature, the outlet of the sixth hot air circulating oven records the pre-cooling temperature, the outlet of the eleventh hot air circulating oven collects the final curing temperature, and the core material winding mechanism 117 detects the residual thermal stress of the core material before winding.

[0073] Eleven hot air circulating ovens, each with a temperature gradient display, and sequentially divided into rapid rise zone, constant temperature zone, slow descent zone, and rapid descent zone:

[0074] The first and second hot air circulating ovens are in the rapid rise zone: target temperature difference ≤35℃, fluctuation ±5℃.

[0075] The third to seventh hot air circulating ovens are in the constant temperature zone: target temperature difference ≤15℃, fluctuation ±3℃.

[0076] The eighth and ninth hot air circulating ovens are slow-fall zones: target temperature difference ≤20℃, fluctuation ±4℃.

[0077] The tenth and eleventh hot air circulating ovens are in the rapid temperature drop zone: target temperature difference ≤25℃, fluctuation ±5℃.

[0078] The three-parameter linkage control method of moisture content, temperature, and velocity is as follows:

[0079] Moisture content-driven speed regulation: When the moisture content at the inlet of the first hot air circulating oven is greater than the preset ideal value, the conveyor belt speed is reduced and the temperature of the rapid rise zone is increased.

[0080] Temperature deviation compensation: If the measured temperature in the constant temperature zone is lower than the set value, the conveyor belt speed will be reduced synchronously.

[0081] Thermal stress synergy: If the temperature difference between adjacent hot air circulating ovens is greater than 20°C, increase the temperature of the downstream hot air circulating oven and reduce the conveyor belt speed.

[0082] Cooling closed loop: For every 1°C deviation in the cooling pool temperature, the conveyor belt speed is compensated by 0.1 m / min in the reverse direction.

[0083] Production line control system, such as Figure 4 As shown, a microwave sensor array is used to detect the moisture content in real time and generate a global moisture content deviation e(t). At the same time, temperature sensors are used to monitor the temperature distribution of 11 ovens and calculate the average temperature offset ΔT. avgBased on this, a dual-PID coupled control architecture is constructed. The outer loop takes the moisture content deviation e(t) as input and dynamically adjusts the production line speed V(t) as output, changing the residence time of the material in the oven, thereby indirectly controlling the moisture content. The inner loop detects the actual moisture content W at the nth oven inlet using a microwave sensor. n (t), and the target moisture content at the inlet of the nth oven. The difference is calculated to obtain the moisture content deviation at the inlet of the nth oven. Using this as input, the output oven temperature T is dynamically adjusted according to the rate of change of velocity dV / dt. n (t), and adjust the oven temperature distribution accordingly. The outer loop output (speed correction) and the inner loop output (temperature correction) are fed back to each other through the weighting coefficient γ to form coordinated control, and generate the final command to be sent to the control actuator.

[0084] The proposed dual-PID cross-coupled control method dynamically allocates control weights for velocity and temperature based on the moisture content error, wherein the outer loop controller V(t) and the inner loop controller T... n (t) Defining coupling variables through their mutual influence:

[0085] e(t) = W t arg et -W(t)

[0086]

[0087] In the formula, W target Let W(t) be the target moisture content, W(t) be the actual moisture content, e(t) be the overall moisture content deviation, and T be the total moisture content deviation. n The current temperature of the nth hot air circulating oven. ΔT is the reference temperature of the nth hot air circulating oven. avg This represents the average temperature deviation of the hot air circulating oven.

[0088] The coupling equation between the conveyor belt speed and the temperature of the hot air circulating oven is:

[0089]

[0090]

[0091] In the formula, α is the coupling coefficient of temperature to velocity, β is the coupling coefficient of velocity to temperature, and e n (t) represents the moisture content deviation at the inlet of the nth hot air circulating oven. W represents the target moisture content at the inlet of the nth hot air circulating oven. n (t) represents the actual moisture content at the inlet of the nth hot air circulating oven, K p1 K i1 K d1 K p2 Ki2 K d2 These are the parameters for a dual PID controller.

[0092] Coupling mechanism: The outer loop output speed correction and the inner loop output temperature correction are fed back to each other through a weighting coefficient γ, forming coordinated control, and generating the final command as follows:

[0093] u final =γ·V(t)+(1-γ)·T n (t).

[0094] The weighting coefficient γ is dynamically adjusted based on the moisture content deviation.

[0095] When |e(t)|>2%, γ→1, the system prioritizes suppressing moisture content deviation by adjusting the transmission speed.

[0096] When |e(t)| < 0.8%, γ → 0, the system prioritizes fine compensation by adjusting the temperature.

[0097] When 0.8% < |e(t)| < 2%, The inner loop of the system fine-tunes the temperature, while the outer loop maintains a stable speed.

[0098] The production line's conveyor speed is dynamically adjustable from 1.5 to 8.0 m / min, with the drive motor equipped with a speed sensor providing real-time feedback to the edge controller. Additionally, the edge computing controller includes dynamic limiting protection, specifically:

[0099] Emergency stop threshold, global moisture content deviation: |e(t)|>5%.

[0100] Acceleration safety constraint, velocity mutation rate: |dV / dt| ≤ 0.5 m / min 2 .

[0101] Thermal stress safety constraints, temperature difference between adjacent hot air circulating ovens: |T (n+1) -T n ≤25℃.

[0102] In addition, the present invention can also establish a curing efficiency coefficient database, using the change in moisture content ΔW, temperature gradient ΔT, and linear velocity V as input variables, and output the optimal combination of process parameters.

[0103] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent transformations or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A smart production line for Class A fire-resistant core materials based on temperature-speed joint control, characterized in that, include: The raw material mixing and conveying system initially mixes and fully stirs inorganic powder and adhesive in a certain proportion, and then conveys them to the conveyor belt through a funnel pipe. A nonwoven fabric bonding and primary peeling system includes a nonwoven fabric bonding mechanism and a primary peeling mechanism. The nonwoven fabric bonding mechanism includes first, second, third, and fourth unwinding mechanisms located on both sides of a conveyor belt. The first and second unwinding mechanisms simultaneously release a single layer of nonwoven fabric from the starting end of the conveyor belt, forming a double-layer nonwoven fabric below the core material located above the conveyor belt, supporting the slurry extruded through a funnel pipe. The third and fourth unwinding mechanisms simultaneously release a single layer of nonwoven fabric above the conveyor belt to press and cover the slurry, forming a double-layer nonwoven fabric above the core material. The primary peeling mechanism includes first and second winding mechanisms located in the conveyor belt process of the raw material mixing and conveying system, used to peel off the outer nonwoven fabric on the upper surface and the outer nonwoven fabric on the lower surface of the core material after being extruded by a single-roll mill. The multi-parameter joint control system consists of a moisture content control system and a baking system. The baking system includes several hot air circulating ovens arranged between the conveyor belts of the raw material mixing and conveying system. Temperature sensors are arranged at the inlet / outlet of each section of the hot air circulating oven, forming a temperature sensor array. The moisture content control system includes a moisture content detection device, a control execution mechanism, and a decision-making mechanism. The moisture content detection device includes a microwave sensor array arranged between the several hot air circulating ovens. The control execution mechanism is equipped with a transmission speed controller and an oven temperature control unit. The decision-making mechanism is equipped with an edge computing controller, which, based on the temperature and moisture content values ​​detected by the temperature sensor array and the microwave sensor array, performs coordinated intelligent control of the transmission speed of the raw material mixing and conveying system conveyor belt and the temperature of the baking system through the transmission speed controller and the oven temperature control unit. The specific process of collaborative intelligent regulation by edge computing controller is as follows: A dual PID cross-coupling control method is proposed, which dynamically allocates control weights for speed and temperature based on the moisture content error, wherein the outer loop controller V(t) and the inner loop controller T... n (t) Defining coupling variables through their mutual influence: ； ； In the formula, For the target moisture content, This represents the actual moisture content. For the overall moisture content deviation, The current temperature of the nth hot air circulating oven. The reference temperature for the nth hot air circulating oven is... This represents the average temperature deviation of the hot air circulating oven. The coupling equation between the conveyor belt speed and the temperature of the hot air circulating oven is: ； ； In the formula, α is the coupling coefficient of temperature to velocity, and β is the coupling coefficient of velocity to temperature. The deviation of the moisture content at the inlet of the nth hot air circulating oven. The target moisture content at the inlet of the nth hot air circulating oven. K represents the actual moisture content at the inlet of the nth hot air circulating oven. p1 K i1 K d1 K p2 K i2 K d2 These are the parameters for a dual PID controller; Coupling mechanism: The outer loop output speed correction and the inner loop output temperature correction are fed back to each other through a weighting coefficient γ, forming coordinated control, and generating the final command as follows: ； The weighting coefficient γ is dynamically adjusted based on the moisture content deviation. when As γ→1, the system prioritizes suppressing moisture content deviation by adjusting the transmission speed. when As γ→0, the system prioritizes temperature adjustment to achieve fine compensation. when , The inner loop of the system fine-tunes the temperature, while the outer loop maintains a stable speed. The cooling and secondary stripping system includes a cooling pool located between several hot air circulating ovens, third and fourth winding mechanisms, a first twin-roll mill, and a core material winding mechanism. After being baked in several hot air circulating ovens, the core material enters the cooling pool for cooling. Then, the inner nonwoven fabric on the upper surface and the inner nonwoven fabric on the lower surface are stripped by the third and fourth winding mechanisms, respectively. After passing through several hot air circulating ovens again, the core material passes through the twin-roll mill and the core material winding mechanism in sequence.

2. The intelligent production line for Class A fire-resistant core material based on temperature-speed joint control according to claim 1, characterized in that, The raw material mixing and conveying system puts inorganic powder and glue into the feeder in a certain proportion for preliminary mixing, and then conveys them to the mixing tank through the closed feeder. In the mixing tank, the inorganic powder and glue are fully stirred to make a fireproof slurry, and then conveyed to the conveyor belt through the funnel pipe.

3. The intelligent production line for Class A fire-resistant core material based on temperature-speed joint control according to claim 1, characterized in that, The nonwoven fabric bonding mechanism also includes a first fixed wheel, a second fixed wheel, and a mixing box. The first unwinding mechanism, the second unwinding mechanism, the third unwinding mechanism, and the fourth unwinding mechanism are respectively arranged on both sides of the mixing box. The mixing box is connected to the mixing tank, and its lower end is connected to the funnel pipe. The first fixed wheel is arranged between the conveyor belts below the funnel pipe and close to the third unwinding mechanism and the fourth unwinding mechanism, and the surface of the first fixed wheel is flush with the surface of the conveyor belt. The second fixed wheel is rotatably arranged directly above the first fixed wheel. The nonwoven fabric released by the first unwinding mechanism and the second unwinding mechanism extends along the conveyor belt conveying direction. The nonwoven fabric released by the third unwinding mechanism and the fourth unwinding mechanism passes around the second fixed wheel and is in the same direction as the conveyor belt conveying direction. All four layers of nonwoven fabric pass between the first fixed wheel and the second fixed wheel and are conveyed along the conveyor belt direction, pressed and covered with slurry to form a double-layer nonwoven fabric wrapping structure for the core material.

4. The intelligent production line for Class A fire-resistant core material based on temperature-speed joint control according to claim 1, characterized in that, The first winding mechanism is located above the rear conveyor belt of the single-roll mill. The first hot air circulating oven is located between the first winding mechanism and the second winding mechanism. The second winding mechanism is located below the conveyor belt after the first hot air circulating oven. First, the first winding mechanism peels off the outer layer of nonwoven fabric on the upper surface and sends it into the first hot air circulating oven for heating. Then, the second winding mechanism located below the conveyor belt peels off the outer layer of nonwoven fabric on the lower surface, completing the first stage of nonwoven fabric peeling process.

5. The intelligent production line for Class A fire-resistant core material based on temperature-speed joint control according to claim 1, characterized in that, The baking system has 11 hot air circulating ovens, with the second to sixth hot air circulating ovens arranged sequentially, and the seventh to eleventh hot air circulating ovens arranged sequentially. The second to sixth hot air circulating ovens and the seventh to eleventh hot air circulating ovens are connected by conveyor belts. A cooling pool and third and fourth winding mechanisms are provided between the sixth and seventh hot air circulating ovens. A first rolling mill is also provided between the fifth and sixth hot air circulating ovens. A second rolling mill is provided between the seventh and eighth hot air circulating ovens. A second double-roll rolling mill is provided between the eighth and ninth hot air circulating ovens.

6. The intelligent production line for Class A fire-resistant core material based on temperature-speed joint control according to claim 5, characterized in that, The cooling pool is equipped with heating rods and heat exchangers. The water temperature is monitored in real time by a temperature sensor. The surface of the cooling pool is also equipped with a first drive wheel, a second drive wheel, and a third drive wheel, which form a certain angle with each other. The core material wrapped with non-woven fabric is transported through the first drive wheel, the second drive wheel, and the third drive wheel and then through the conveyor belt after the cooling pool. The third and fourth winding mechanisms are respectively set above and below the conveyor belt to wind up the inner non-woven fabric on the upper surface and the inner non-woven fabric on the lower surface of the peeled core material.

7. The intelligent production line for Class A fire-resistant core material based on temperature-speed joint control according to claim 5, characterized in that, The microwave sensor array is deployed at the inlet of the first hot air circulating oven, the outlet of the third hot air circulating oven, the outlet of the sixth hot air circulating oven, the inlet of the seventh hot air circulating oven, and the outlet of the eleventh hot air circulating oven. Infrared thermal imagers are added at the inlet of the first hot air circulating oven, the outlet of the third hot air circulating oven, the outlet of the sixth hot air circulating oven, the outlet of the eleventh hot air circulating oven, and the core material winding mechanism. The inlet of the first hot air circulating oven monitors the initial temperature of the slurry, the outlet of the third hot air circulating oven detects the initial curing temperature, the outlet of the sixth hot air circulating oven records the pre-cooling temperature, the outlet of the eleventh hot air circulating oven collects the final curing temperature, and the core material winding mechanism detects the residual thermal stress of the core material before winding.

8. The intelligent production line for Class A fire-resistant core material based on temperature-speed joint control according to claim 5, characterized in that, The 11 hot air circulating ovens are divided into the following functional temperature zones and temperature tolerances are defined: The first and second hot air circulating ovens are in the rapid rise zone: target temperature difference ≤35℃, fluctuation ±5℃; The third to seventh hot air circulating ovens are in the constant temperature zone: target temperature difference ≤15℃, fluctuation ±3℃; The eighth and ninth hot air circulating ovens are slow-fall zones: target temperature difference ≤20℃, fluctuation ±4℃; The tenth and eleventh hot air circulating ovens are in the rapid temperature drop zone: target temperature difference ≤25℃, fluctuation ±5℃; The three-parameter linkage control method of moisture content, temperature, and velocity is as follows: Moisture content-driven speed regulation: When the moisture content at the inlet of the first hot air circulating oven is greater than the preset ideal value, the conveyor belt speed is reduced and the temperature of the rapid rise zone is increased; Temperature deviation compensation: If the measured temperature in the constant temperature zone is lower than the set value, the conveyor belt speed will be reduced synchronously. Thermal stress coordination: If the temperature difference between adjacent hot air circulating ovens is greater than 20°C, increase the temperature of the downstream hot air circulating oven and reduce the conveyor belt speed. Cooling closed loop: For every 1°C deviation in the cooling pool temperature, the conveyor belt speed is compensated by 0.1 m / min in the reverse direction.

9. The intelligent production line for Class A fire-resistant core material based on temperature-speed joint control according to claim 1, characterized in that, The edge computing controller also includes dynamic limiting protection, specifically: Emergency stop threshold, global moisture content deviation: ; Acceleration safety constraint, velocity mutation rate: |dV / dt| ≤ 0.5 m / min 2 ; Thermal stress safety constraints, temperature difference between adjacent hot air circulating ovens: |T （n+1） - T n ≤25℃.

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