Production process and system of low-temperature-resistant rubber acoustic membrane

Abstract

The invention relates to the technical field of production of rubber membrane materials, in particular to a production process and system of a low-temperature-resistant rubber acoustic membrane. The method comprises the following steps: taking AEM as a base material, and completing the basic preparation of the low-temperature-resistant rubber acoustic membrane through the links of banburying and rubber mixing, open milling and sheet discharging, coating and membrane preparation, and vulcanization and shaping; dividing a current low-temperature-resistant rubber acoustic membrane detection sub-region, acquiring detection data of each link of the sub-region for the same detection batch, and performing detection link linkage to generate a comprehensive detection result of the detection sub-region; dynamically adjusting a parameter strategy based on the deviation level and source of the comprehensive detection result; the system comprises a rubber acoustic membrane preparation module, a detection step linkage module and a production parameter dynamic adjustment module. Through the mode, the accuracy of a production detection result is improved, so that the production quality of the low-temperature-resistant rubber acoustic membrane is improved.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of rubber film material production, in particular to a production process and system of a low-temperature-resistant rubber acoustic film. BACKGROUND

[0002] The low-temperature-resistant rubber acoustic film needs to meet the cooperative requirements of low-temperature resistance, mechanical strength and acoustic insulation performance, and the production process covers multiple links such as formula preparation, rubber mixing and film making, the parameters of the links are related to each other, and the performance of the final product is significantly affected. At present, the existing production method has the following core problems: Preparation and detection are disconnected: the detection of each production link (such as banburying, open mixing and coating) is independently carried out, the detection data is not linked for analysis, the chain effect of the previous links on the subsequent processes and the performance of the finished product cannot be reflected in time, resulting in one-sided detection results and difficulty in accurately locating quality problems.

[0003] Parameter adjustment lags behind: the production parameters (such as banburying temperature, open mixing roll distance and coating speed) are fixedly set, and only backtracking adjustment is carried out after the finished product detection is unqualified, there is a lack of dynamic optimization mechanism based on real-time detection data, resulting in prolonged production cycle, high raw material loss rate (usually more than 8%) and poor performance stability of the finished product (the acoustic volume deviation between batches can reach 3-5 dB).

[0004] Insufficient detection accuracy: single-link detection indicators (such as only detecting the Mooney viscosity of banburying rubber) cannot comprehensively represent the comprehensive performance of the product, and the situation that the intermediate product detection is qualified but the performance of the finished product does not meet the standards may occur.

[0005] Therefore, it is necessary to provide a production process and system for improving the accuracy of detection results and the stability of product quality through linkage analysis of full-process detection data and real-time parameter optimization. SUMMARY

[0006] The application aims to provide a production process and system of a low-temperature-resistant rubber acoustic film, which can achieve linkage analysis of full-process detection data and real-time parameter optimization, and improve the accuracy of detection results and the stability of product quality.

[0007] To achieve the above-mentioned purpose, a production process of a low-temperature-resistant rubber acoustic film is adopted, which comprises the following steps: AEM is used as a base material, and the basic preparation of the low-temperature-resistant rubber acoustic film is completed through the links of banburying, open mixing, coating and vulcanization; The current low-temperature-resistant rubber acoustic film detection sub-area is divided, the detection data of each link of the sub-area is obtained for the same detection batch, the links are linked, and the comprehensive detection result of the detection sub-area is generated; Adjust the parameter strategy dynamically based on the deviation level and source of the comprehensive detection result.

[0008] In the step of preparing the low-temperature-resistant rubber acoustic film based on the AEM as the base material and through the steps of mixing, sheeting, coating, film forming, and vulcanization, the low-temperature-resistant rubber acoustic film is prepared. The mixing material is prepared by using a multi-stage raw material input method, wherein the raw material input method includes: a first stage of softening raw rubber, a second stage of mixing additives, a third stage of adding reinforcing agents, and a fourth stage of adding a vulcanization system. The roll gap of the open mill is adjusted, and the open mill is used to prepare the open mill sheet. The open mill sheet is subjected to melting treatment to obtain a glue solution. After the glue solution is uniformly coated on the surface of the base material, it is sequentially dried and vulcanized to obtain a film material.

[0009] After the step of adjusting the roll gap of the open mill, using the open mill to prepare the open mill sheet, and melting the open mill sheet to obtain a glue solution, and after the glue solution is uniformly coated on the surface of the base material, it is sequentially dried and vulcanized to obtain a film material: After the film material is naturally cooled to room temperature, it is wound to obtain a low-temperature-resistant rubber acoustic film base product.

[0010] In the step of dividing the current low-temperature-resistant rubber acoustic film detection sub-area, obtaining the detection data of each sub-area for the same detection batch, and performing detection link linkage to generate the comprehensive detection result of the detection sub-area: Actual data of the detection index corresponding to each sub-area is collected in time sequence; wherein the collected data includes: low-temperature-resistant performance data, acoustic performance data, and mechanical performance data; The influence weight of the detection index on the core performance in each sub-area is determined; The comprehensive result is qualitatively judged and the deviation source is located by combining the index standard reaching degree and the influence weight, and the comprehensive detection result of the detection sub-area is generated.

[0011] Before the step of collecting actual data of the detection index corresponding to each sub-area in time sequence; wherein the collected data includes: low-temperature-resistant performance data, acoustic performance data, and mechanical performance data: For the same production batch, three independent detection sub-areas are divided.

[0012] In the step of collecting actual data of the detection index corresponding to each sub-area in time sequence; wherein the collected data includes: low-temperature-resistant performance data, acoustic performance data, and mechanical performance data: The data collected for the same production batch is given an identifier.

[0013] In the step of adjusting the parameter strategy dynamically based on the deviation level and source of the comprehensive detection result: According to the comprehensive detection result of the detection sub-area, target adjustment is carried out for each sub-area respectively, and the production parameters are adjusted.

[0014] After the step of adjusting the production parameters according to the comprehensive detection result of the detection sub-area, respectively for each sub-area: The production parameter adjustment data is obtained, and is put into use in the next production batch.

[0015] After the step of obtaining the production parameter adjustment data and putting into use in the next production batch: The change of the subsequent raw material batch is detected, and the comprehensive detection result of the current batch is updated.

[0016] The application also provides a production system of low-temperature-resistant rubber acoustic film, comprising a rubber acoustic film preparation module, a detection step linkage module and a production parameter dynamic adjustment module. The rubber acoustic film preparation module is used to complete the basic preparation of the low-temperature-resistant rubber acoustic film by taking AEM as the base material and through the steps of internal mixing, sheeting out, coating, film forming and vulcanization. The detection step linkage module is used to divide the detection sub-area of the current low-temperature-resistant rubber acoustic film, obtain the detection data of each step of the sub-area for the same detection batch, and perform linkage of the detection steps to generate the comprehensive detection result of the detection sub-area. The production parameter dynamic adjustment module is used to dynamically adjust the parameter strategy based on the deviation level and source of the comprehensive detection result.

[0017] The production process and system of the low-temperature-resistant rubber acoustic film are used to perform the following steps by using the rubber acoustic film preparation module, the detection step linkage module and the production parameter dynamic adjustment module: taking AEM as the base material and completing the basic preparation of the low-temperature-resistant rubber acoustic film through the steps of internal mixing, sheeting out, coating, film forming and vulcanization; dividing the detection sub-area of the current low-temperature-resistant rubber acoustic film, obtaining the detection data of each step of the sub-area for the same detection batch, and performing linkage of the detection steps to generate the comprehensive detection result of the detection sub-area; dynamically adjusting the parameter strategy based on the deviation level and source of the comprehensive detection result; and generating the comprehensive detection result of the current low-temperature-resistant rubber acoustic film by linking the detection steps in each production step, and dynamically adjusting the production parameters of the low-temperature-resistant rubber acoustic film according to the comprehensive detection result, so as to increase the accuracy of the production detection result and improve the production quality of the low-temperature-resistant rubber acoustic film. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions of the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description only represent some of the embodiments of the present application, and for those skilled in the art, other drawings can also be obtained from these drawings without creative labor.

[0019] Figure 1 is a step flow chart of the production process of the low-temperature-resistant rubber acoustic film of the present application.

[0020] Figure 2 is a step flow chart of S100 of the present application.

[0021] Figure 3 is a step flow chart of S200 of the present application.

[0022] Figure 4 is a step flow chart of S300 of the present application.

[0023] Figure 5 is a structure principle diagram of the production system of the low-temperature-resistant rubber acoustic film of the present application.

[0024] Figure 6 is a structure principle diagram of the electronic device of the present application.

[0025] 401-rubber acoustic film preparation module, 402-detection step linkage module, 403-production parameter dynamic adjustment module. DETAILED DESCRIPTION

[0026] The exemplary embodiments will be described in detail herein with reference to the attached drawings. When the following description refers to the drawings, the same numbers in different drawings represent the same or similar elements unless otherwise indicated. The implementations described in the following exemplary embodiments do not represent all implementations consistent with the present application.

[0027] The terms used in this application are merely for the purpose of describing specific embodiments, and are not intended to limit the present application. The singular forms "a", "an" and "the" used in this application and the appended claims are also intended to include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein means and includes any or all possible combinations of one or more associated listed items.

[0028] It should be understood that, although the terms first, second, third, etc. can be employed in this application to describe various information, the information is not to be limited to these terms. These terms are only used to distinguish one category of information from another. For example, without departing from the scope of the application, first information could also be referred to as second information, and, similarly, second information could also be referred to as first information. Depending on the context, the word "if' as used herein can be interpreted to mean "when" or "in response to determining." The term "couple" as used herein is intended to mean either a direct connection between two components or an indirect connection through one or more additional components.

[0029] Referring to Figures 1-4 The application provides a production process of a low-temperature-resistant rubber acoustic film, comprising the following steps: S100: taking AEM as a base material, and completing the basic preparation of the low-temperature-resistant rubber acoustic film through the steps of mixing and mixing, sheeting, coating, film forming and vulcanization.

[0030] In this embodiment, AEM is taken as a base material, and the basic preparation of the low-temperature-resistant rubber acoustic film is completed through the steps of mixing and mixing, sheeting, coating, film forming and vulcanization. The specific process is as follows: S101: a multi-stage raw material feeding mode is adopted to obtain a mixed rubber; wherein the raw material feeding mode comprises: a first stage of softening raw rubber, a second stage of mixing auxiliary agent, a third stage of adding reinforcing agent, and a fourth stage of adding vulcanization system; S102: adjusting the roll gap of the open mill, using the open mill to obtain an open mill sheet, melting the open mill sheet to obtain a glue solution, and then sequentially drying and vulcanizing the glue solution on the surface of the base material to obtain a film material; S103: after the film material is naturally cooled to room temperature, it is wound up to obtain a low-temperature-resistant rubber acoustic film basic product.

[0031] In the above process, AEM (ethylene acrylate rubber) is taken as a core base material, and the basic preparation of the low-temperature-resistant rubber acoustic film is completed through four continuous processes of mixing and mixing, sheeting, coating and film forming, and vulcanization. The operation and parameters of each link are as follows: (I) mixing and mixing process (uniform mixing of rubber), Equipment and raw material preparation: clean the mixing chamber of the mixer and preheat it to 85-90℃, and set the rotor speed to 45-55r / min.

[0032] Stage mixing operation: First stage (raw rubber softening): put in AEM raw rubber, mix for 4 min, and then enter the next stage after the raw rubber is completely wrapped around the roller (no block-shaped residue on the surface).

[0033] Second stage (additives mixing): Add antioxidant KY-405 and part of DINP, continue mixing for 2.5 min, ensure that the additives are evenly dispersed in the raw rubber, and the temperature in the mixing chamber is controlled at 95-100℃.

[0034] Third stage (reinforcing agent addition): Mix carbon black and white carbon black evenly, add in two times (with an interval of 1.5 min), and increase the mixing temperature to 105-110℃ to avoid agglomeration of the reinforcing agent. This stage lasts for 3 min.

[0035] Fourth stage (vulcanizing system addition): Add part of DINP, DCP vulcanizing agent and CZ accelerator, and mix for 1.5 min. Monitor the temperature throughout the process to ensure it does not exceed 120℃ (to prevent premature decomposition of the vulcanizing agent). When the rubber has a uniform color and no particle feel, discharge the material to obtain the mixed rubber.

[0036] (2) Mixing and sheeting process, Equipment adjustment: Adjust the front roller temperature of the mixing machine to 55-60℃, and the rear roller temperature to 50-55℃ (the front roller is slightly higher to facilitate the rubber wrapping). Set the initial roller gap to 4mm.

[0037] Rubber processing flow: Roller wrapping and thinning: Put the mixed rubber into the mixing machine. After the rubber is completely wrapped (without sliding and without bubbles), reduce the roller gap to 1.5mm and perform 4 times of thinning (fold the rubber after each thinning) to release the internal stress of the rubber.

[0038] Thickness setting and sheeting: After thinning, gradually adjust the roller gap to 2.5mm and continuously sheet 3 times. Use a scraper to remove impurities on the surface of the rubber to ensure uniform thickness (deviation ≤0.2mm) and smooth surface without cracks. Obtain the mixed rubber sheet.

[0039] (3) Coating and film forming process (rubber and substrate compounding), Substrate and equipment preparation: Select a 75μm thick PET film (treated by corona, surface tension ≥38mN / m) and install it on the unwinding device of the coating machine with a tension of 20-25N. Put the mixed rubber sheet into the melting device of the coating machine and heat it to 135-145℃. Stir at a speed of 35r / min for 20min to melt the rubber into a uniform liquid (without clumps and bubbles).

[0040] Coating and drying operation: Coating parameter setting: Coating speed 1.5m / min, knife pressure 0.25MPa, coating thickness set to 0.3mm (adjustable according to product requirements).

[0041] Three-stage drying: after coating, the film material enters the drying channel, the front section (pre-drying) temperature is 85℃ (remove a small amount of volatile), the middle section (main drying) temperature is 105℃ (glue setting), the rear section (cooling setting) temperature is 75℃, the total drying time is 6min, and the unvulcanized coated semi-finished film is obtained.

[0042] (Four) vulcanization setting process (performance curing), Vulcanization equipment and parameters: using electric heating vulcanization tank, the coated semi-finished film is placed flat in the vulcanization frame (avoiding overlapping extrusion), the vulcanization temperature is set to 170℃, the pressure is 0.6MPa, and the vulcanization time is 12min.

[0043] Cooling and winding: after vulcanization is completed, the vulcanization tank is opened and naturally cooled to room temperature (about 25℃), and the winding machine is used to wind at a speed of 5m / min, and the low-temperature-resistant rubber acoustic film basic finished product is obtained, which enters the subsequent detection link.

[0044] S200: dividing the current low-temperature-resistant rubber acoustic film detection sub-area, obtaining the detection data of each link of the sub-area for the same detection batch, and performing link linkage to generate the comprehensive detection result of the detection sub-area.

[0045] In the embodiment, the current low-temperature-resistant rubber acoustic film detection sub-area is divided, the detection data of each link of the sub-area is obtained for the same detection batch, and the link linkage is performed to generate the comprehensive detection result of the detection sub-area. The specific process is as follows: S201: dividing three independent detection sub-areas for the same production batch; S202: collecting the actual data of the corresponding detection index of each sub-area in time sequence, and giving an identifier to the collected data of the same production batch; wherein the collected data includes: low-temperature-resistant performance data, acoustic performance data, and mechanical performance data; S203: determining the influence weight of the detection index in each sub-area on the core performance; S204: combining the index standard degree and the influence weight to qualitatively determine the comprehensive result and locate the deviation source, and generating the comprehensive detection result of the detection sub-area.

[0046] In the above process, the low-temperature-resistant rubber acoustic film of the same production batch is selected as the detection object, the products of this batch use 75μm PET film as the substrate, and the production capacity is 500m 2According to the core performance requirements of the product, the detection system is divided into three independent detection sub-regions covering the whole production process. The first is the low-temperature resistance area, the core target is to ensure that the film material can maintain elasticity and not become brittle at-40°C, and to ensure the stability of the acoustic performance under low-temperature conditions, covering the raw material, mixing, coating and vulcanization four production links; the second is the acoustic performance area, the core target is to make the average sound insulation volume of the film material in the frequency range of 100-4000Hz reach more than 25dB to meet the noise reduction demand, covering the raw material, mixing, open mixing and coating four links; the third is the mechanical performance area, the core target is to ensure that the film material has sufficient structural stability, the tensile strength is not less than 10MPa, the elongation at break is not less than 350%, and the tear strength is not less than 30kN / m, covering the raw material, mixing, open mixing and vulcanization four links. The functions and detection boundaries of the three sub-regions are clear, avoiding repeated detection of indicators, and ensuring that each performance dimension can be accurately detected. S202: Collecting actual data of detection indicators corresponding to each sub-region in time sequence, and giving an identifier to the collected data of the same production batch; wherein the collected data includes: low-temperature resistance performance data, acoustic performance data, mechanical performance data The data is collected strictly according to the sequence of the production process (raw material→mixing→open mixing→coating→vulcanization), and the results are recorded immediately after the detection of each link to prevent data lag or confusion. The collected low-temperature resistance performance data includes: the purity and flash point of DINP in the raw material, the Mooney viscosity of the mixing rubber, the glue viscosity of the coating semi-finished product, the brittleness, storage modulus and loss factor peak temperature of the finished product after being placed at-40°C for 24 hours. The acoustic performance data includes: the oil absorption value of carbon black and the specific surface area of white carbon black in the raw material, the dispersion degree of reinforcing agent in the mixing rubber, the thickness deviation of the open mixing rubber sheet, and the average sound insulation volume of the finished product at a frequency of 100-4000Hz. The mechanical performance data includes: the Mooney viscosity and unvulcanized tensile strength of AEM raw rubber, the scorch time and normal vulcanization time of the mixing rubber, the unvulcanized tensile strength and elongation at break of the open mixing rubber sheet, and the tensile strength, elongation at break and tear strength of the finished product. At the same time, all the data collected for the same production batch is given a unique identifier, the identifier format is "batch number-sub-region code-link code-indicator code-detection time", for example, the detection data of the purity of DINP in the raw material in sub-region A, the identifier can be set as "2025002-A-YL-DINP-C-202509080930" (wherein 2025002 is the batch number, A represents the low-temperature resistance performance area, YL represents the raw material link, DINP-C represents the DINP purity indicator, and 202509080930 is the detection time, accurate to minutes), through the identifier, the data can be traced and avoided to be confused with other batch data. Based on the historical test data of 50 production batches in the past 12 months and the results of multiple orthogonal tests, the influence degree of each test index in each test sub-area on the core performance of the area was analyzed to determine the influence weight of different indexes (the total weight of all indexes is 100%, the greater the influence on the core performance, the higher the weight). In the low temperature resistance performance area, the finished product loss factor peak temperature directly reflects the low temperature elasticity, which is the core index, and the weight is set to 40%; the purity of raw material DINP affects the rubber glass transition temperature, which is a basic key index, and the weight is 25%; the Mooney viscosity of the banbury compound indirectly affects the low temperature resistance performance by affecting the processing uniformity of the rubber compound, which is a process index, and the weight is 20%; the viscosity of the coating semi-finished product glue solution only affects the coating uniformity, and has less effect on the low temperature resistance performance, which is an auxiliary index, and the weight is 15%. In the acoustic performance area, the dispersion degree of the banbury compound reinforcing agent directly determines the internal friction and sound insulation effect of the rubber compound, and the weight is 45%; the average sound insulation volume of the finished product is the direct performance target, and the weight is 25%; the thickness deviation of the open rubber sheet affects the uniformity of the damping layer of the film material, and the weight is 15%; the carbon black oil absorption value and the white carbon black specific surface area in the raw material are basic parameters, and the total weight is 15%. In the mechanical performance area, the scorch time and the positive curing time of the banbury compound determine the crosslinking structure of the rubber, which directly affects the mechanical performance, and the weight is 40%; the tensile strength and the elongation at break of the finished product are the direct mechanical targets, and the weight is 30%; the unvulcanized mechanical performance of the open rubber sheet reflects the processing stability of the rubber compound, and the weight is 15%; the raw material AEM raw rubber parameters are basic indexes, and the weight is 15%. The determination criteria of the clear target standard: the detection value is within the qualified standard range, or the key indicators deviation is not more than 1%, the general indicators deviation is not more than 3%, which is qualified; the detection value exceeds the qualified standard, but the key indicators deviation is not more than 3%, the general indicators deviation is not more than 5%, which is slightly unqualified; the detection value exceeds the qualified standard, and the key indicators deviation is more than 3%, the general indicators deviation is more than 5%, which is unqualified. Then the comprehensive result determination rules are formulated: all indicators are qualified, or the weight sum of slightly unqualified indicators is not more than 10%, the comprehensive result is "excellent"; the weight sum of slightly unqualified indicators is between 10% and 20%, and there is no unqualified indicator, the comprehensive result is "qualified"; the weight sum of slightly unqualified indicators is between 20% and 30%, or there is slightly unqualified situation of high weight indicators (weight more than 30%), the comprehensive result is "qualified (need to adjust)"; there is unqualified indicator, or the weight sum of slightly unqualified indicators is more than 30%, the comprehensive result is "unqualified". According to the above standard and rule, each sub-region is determined: taking the low temperature resistance performance area as an example, the detection data shows that the purity of raw material DINP is 99.4% (qualified standard ≥ 99.5%, slightly unqualified, weight 25%), the peak temperature of finished product loss factor is -34℃ (qualified standard ≤ -35℃, slightly unqualified, weight 40%), the Mooney viscosity of mixing rubber is 68 (qualified standard 50~70, qualified), the viscosity of coating semi-finished product glue is 7200 mPa·s (qualified standard 5500~7500 mPa·s, qualified). Although the weight sum of slightly unqualified indicators is 65%, the actual DINP purity deviation is only 0.1% (deviation rate 0.2%), the peak temperature deviation of loss factor is 1℃ (deviation rate 2.8%), the deviation degree is slight, and the comprehensive result is "qualified" combined with weight determination. Further analysis shows that the Mooney viscosity of mixing rubber is close to the upper limit of the standard, which indirectly causes the mixing uniformity of rubber to be slightly poor, and thus the deviation source is located in the "mixing process". In the acoustic performance area, the dispersion degree of mixing rubber reinforcing agent is 88% (qualified standard ≥ 90%, slightly unqualified, weight 45%), the average sound insulation volume of finished product is 24 dB (qualified standard ≥ 25 dB, slightly unqualified, weight 25%), and other indicators are qualified. The dispersion degree of reinforcing agent deviates by 2% (deviation rate 2.2%), and the sound insulation volume deviates by 1 dB (deviation rate 4%). The slightly unqualified high weight indicators directly affect the core acoustic performance, and the comprehensive result is "qualified (need to adjust)", and the deviation is caused by the addition of reinforcing agent in the mixing process for 2 times with an interval of 1.5 min, which leads to insufficient dispersion, and the deviation link is located in the "mixing process reinforcing agent addition process".In the mechanical property zone, the scorch time of the mixed rubber is 4.8 min (the qualified standard is greater than or equal to 5 min, slightly substandard), the curing time is 23 min (the qualified standard is 18-22 min, slightly substandard), the total weight is 40%; the tensile strength of the finished product is 9.8 MPa (the qualified standard is greater than or equal to 10 MPa, slightly substandard), the elongation at break is 340% (the qualified standard is greater than or equal to 350%, slightly substandard), the total weight is 30%, other indicators meet the standard, and the deviation degree of each indicator is slight (the scorch time deviation is 0.2 min, the curing time deviation is 1 min, the tensile strength deviation is 0.2 MPa, and the elongation at break deviation is 10%). The comprehensive result is "qualified (needs optimization)", the deviation is that the amount of vulcanizing agent in the mixing process is 3.5 parts, which is too much, resulting in too fast vulcanization reaction speed, and the deviation link is located as "mixing process vulcanization system adding process". Finally, the comprehensive detection results of each detection sub-area are generated in the form of a written report. The report includes batch information, detection index data and identifiers of each link, index weight distribution, index standard reaching situation, comprehensive result level, deviation source and preliminary adjustment suggestion, etc., which provides a basis for subsequent parameter adjustment.

[0047] S300: dynamically adjusting the parameter strategy based on the deviation level and source of the comprehensive detection result.

[0048] In this embodiment, the parameter strategy is dynamically adjusted based on the deviation level and source of the comprehensive detection result. The specific process is as follows: S301: adjusting the production parameters according to the comprehensive detection result of each detection sub-area; S302: obtaining the production parameter adjustment data and putting it into use in the next production batch; S303: detecting the change of the subsequent raw material batch and updating the comprehensive detection result of the current batch.

[0049] In the above process, the deviation level (qualified, qualified with adjustment, qualified with optimization) and specific deviation source (involving production links and problems) of each sub-region are determined by referring to the comprehensive detection report of each detection sub-region, a targeted production parameter adjustment scheme is formulated for each sub-region, and it is ensured that the adjustment measures directly correspond to the deviation problems. For the comprehensive result of "qualified" in the low-temperature resistance performance area (the deviation source is that the Mooney viscosity of the banbury compound is too high), the adjustment target is set to reduce the Mooney viscosity of the banbury compound from 68 to the middle of the interval of 50~70 (about 60), which indirectly reduces the peak temperature of the finished product loss factor to below -35℃, the adjustment link focuses on the third stage of the banbury process (the reinforcing agent addition stage), and the temperature of this stage in the original parameters is increased from 105~110℃ to 110~115℃ (the flowability of the AEM compound is enhanced by moderate heating, the reinforcing agent is fully mixed with the compound, and the viscosity of the compound is reduced), and the time is extended from 3min to 3.5min (the mixing time is extended, the local agglomeration of the reinforcing agent is reduced, and the viscosity is further reduced), and the number and interval of the reinforcing agent addition remain unchanged (because the addition rhythm of this batch does not directly cause deviation). For the result of "qualified (with adjustment)" in the acoustic performance area (the deviation source is that the dispersion degree of the reinforcing agent of the banbury compound is insufficient), the adjustment target is to increase the dispersion degree of the reinforcing agent from 88% to more than 90%, and the average sound insulation volume of the finished product reaches more than 25dB, and the adjustment link is the third stage of the banbury process, and the reinforcing agent is added in three times instead of two times (the amount of each addition is equal, the single addition amount is reduced, and the particle agglomeration is avoided), and the addition interval is extended from 1.5min to 2min (sufficient mixing time is given to the reinforcing agent added before), and the temperature of this stage is fixed from the original fluctuation range of 105~110℃ to 110℃ (avoiding temperature fluctuation to cause compound viscosity change to provide a stable environment for dispersion), and at the same time, the rotor speed of the banbury mixer is fixed from the original fluctuation range of 45~55r / min to 50r / min (ensuring uniform shear force to guarantee dispersion effect). For the result of "qualified (with optimization)" in the mechanical performance area (the deviation source is that the curing time parameter of the banbury compound is too long), the adjustment target is to adjust the scorch time from 4.8min to more than 5min, and the cure time from 23min to 18~22min, and the finished product tensile strength and elongation at break reach the standard, and the adjustment link is the fourth stage of the banbury process (the vulcanization system addition stage), and the amount of DCP vulcanizing agent is reduced from 3.5 parts to 3 parts (reducing the concentration of vulcanizing agent, slowing down the vulcanization reaction start speed, and prolonging the scorch time), and the temperature of this stage is fixed from the original fluctuation range of ≤120℃ to 115~120℃ (avoiding too high temperature to accelerate the decomposition of vulcanizing agent), and the time is shortened from 1.5min to 1min (reducing the action time of vulcanizing agent in the banbury process to control the cure time). The parameters of each link are arranged into a production parameter adjustment list, which clearly shows the parameter category (such as mixing temperature, time, raw material adding method, etc.), parameter value before adjustment, parameter value after adjustment, applicable production link, person in charge of execution, and matters needing attention (such as mixing temperature needs real-time monitoring, and the value is recorded every 1 min). One hour before the next production batch (batch number 2025003) is put into production, the production equipment is calibrated comprehensively: the temperature sensor of the mixer is calibrated to ensure that the temperature display deviates from the actual value by not more than 1°C; the timer is calibrated with an error controlled within 5s; the electronic scale (used for weighing raw materials such as vulcanizing agent) is calibrated with an accuracy of 0.01g; the roll gap adjusting device of the open mill is calibrated to ensure that the roll gap adjusting error is not more than 0.05mm. Then the operators of the mixing, batching, and opening links are organized to carry out 15-minute special training, to explain the reasons for parameter adjustment, the specific execution standards after adjustment (such as the dosage of each time for the 3-time addition of reinforcing agent, mixing temperature monitoring frequency, etc.), and the production parameter adjustment list is printed into a prompt card and pasted in a conspicuous position of the corresponding equipment, so as to facilitate the operators to check at any time. During the production process, the operators strictly set the equipment parameters according to the adjustment list, and record the actual execution value of the key parameters (such as mixing temperature, reinforcing agent adding interval time, vulcanizing agent dosage, etc.) every 30 minutes, to ensure that the adjusted parameters are accurately implemented, and at the same time, the quality inspectors are arranged to randomly check the parameter execution situation to avoid operation deviation. In the production process of batch 2025003, the raw materials put in are synchronously batch-traced and performance sampled: through the raw material entry account, the batch numbers of AEM raw rubber, DINP, carbon black, white carbon black and other raw materials are confirmed, and it is judged whether they are the same batch as the last batch (2025002); if they are new batch raw materials, the sampling frequency is additionally increased, the key indicators of the new batch AEM raw rubber, such as Mooney viscosity, unvulcanized tensile strength, the new batch DINP, such as purity, flash point, the new batch carbon black, such as oil absorption value, and the specific surface area of white carbon black, are detected, and it is confirmed whether the performance of the raw materials has a major fluctuation (such as AEM raw rubber Mooney viscosity exceeding the qualified range of 45-60, or DINP purity deviation exceeding 3%), so as to avoid the influence of raw material change on the parameter adjustment effect. After the production of batch 2025003 is completed, the product is re-detected in the whole link according to the collection mode of step S202 and the determination standard of step S204, the latest detection data of each sub-region (such as the Mooney viscosity of the compound in the low-temperature resistance performance area, the peak temperature of the product loss factor, the dispersion degree of the reinforcing agent in the acoustic performance area, the sound insulation volume of the product, the vulcanization characteristics in the mechanical performance area, and the mechanical performance of the product) are obtained, the changes of the core performance indicators of each sub-region before and after adjustment (batch 2025002 and 2025003) are compared, and the actual effect of parameter adjustment is evaluated. If the comprehensive results of each sub-region after adjustment are all improved to "excellent", the adjusted parameters are defined as "standard production parameters" and are included in the production operation instruction book for subsequent regular batch production; if there is still deviation (such as the sound insulation volume of the product in the acoustic performance area is only improved to 24.5 dB, which does not reach 25 dB), the process of steps S200-S302 is repeated, and the parameters are further optimized (such as the addition interval of the reinforcing agent is extended to 2.5 min again). At the same time, a dynamic adaptation plan for raw material batch fluctuation is made, and when the key indicators of the raw materials deviate by more than 2% (such as the Mooney viscosity of AEM raw rubber rises to 65), the detection process of S200 needs to be restarted, the source of the new deviation is located, and the corresponding parameters are adjusted through steps S301-S302, so as to ensure that the production process can continuously adapt to the change of raw materials and maintain the stability of product performance.

[0050] Corresponding to the foregoing embodiments of the production process of the low-temperature-resistant rubber acoustic membrane, the application also provides embodiments of a production system of the low-temperature-resistant rubber acoustic membrane.

[0051] Figure 5 is a block diagram of a production system of a low-temperature-resistant rubber acoustic membrane according to an exemplary embodiment. Referring to Figure 5 , the system can include: a rubber acoustic membrane preparation module 401, a detection step linkage module 402, and a production parameter dynamic adjustment module 403; wherein: The rubber acoustic membrane preparation module 401 is used to complete the basic preparation of the low-temperature-resistant rubber acoustic membrane by taking AEM as the base material and through the steps of banburying, opening, sheeting, coating, membrane making, and vulcanization. The detection step linkage module 402 is used for dividing a current low-temperature-resistant rubber acoustic membrane detection sub-region, acquiring detection data of each link of the sub-region for a same detection batch, and performing detection link linkage to generate a comprehensive detection result of the detection sub-region. The production parameter dynamic adjustment module 403 is used for dynamically adjusting a parameter strategy based on a deviation level and a source of the comprehensive detection result.

[0052] In the embodiment, the rubber acoustic membrane preparation module 401 takes AEM as a base material, and completes the basic preparation of the low-temperature-resistant rubber acoustic membrane through the links of banburying, mixing, sheeting, coating, membrane forming, and vulcanization; the detection step linkage module 402 divides a current low-temperature-resistant rubber acoustic membrane detection sub-region, acquires detection data of each link of the sub-region for a same detection batch, and performs detection link linkage to generate a comprehensive detection result of the detection sub-region; the production parameter dynamic adjustment module 403 dynamically adjusts a parameter strategy based on a deviation level and a source of the comprehensive detection result; through the linkage of the detection links in each production link, the comprehensive detection result of the current low-temperature-resistant rubber acoustic membrane is generated, and the production parameter of the low-temperature-resistant rubber acoustic membrane is dynamically adjusted according to the comprehensive detection result, so as to increase the production detection result accuracy, thereby improving the production quality of the low-temperature-resistant rubber acoustic membrane.

[0053] As to the system in the above embodiment, the specific manner in which each module performs operations has been described in detail in the embodiment of the method, and will not be described in detail here.

[0054] For the system embodiment, since it basically corresponds to the method embodiment, the related parts can be referred to the part of the method embodiment. The device embodiment described above is only schematic, wherein the units described as separate components can or can not be physically separate, and the components displayed as units can or can not be physical units, that is, they can be located in one place or distributed on multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the scheme of the present application. Those skilled in the art can understand and implement it without creative labor.

[0055] Correspondingly, the present application also provides an electronic device, including: one or more processors; a memory for storing one or more programs; when the one or more programs are executed by the one or more processors, the one or more processors implement the production process of the low-temperature-resistant rubber acoustic membrane as described above. As shown in the figure, a hardware structure diagram of a production system of a low-temperature-resistant rubber acoustic membrane provided by an embodiment of the present application is in any device with data processing capability, in addition to the above-mentioned Figure 6 Figure 6 ​In addition to the processor, the memory, and the network interface shown, any data processing capable device in which the apparatus of the embodiments is implemented can also include other hardware according to the actual functions of the data processing capable device, which will not be described herein.

[0056] Accordingly, the present application also provides a computer readable storage medium having computer instructions stored thereon, which, when executed by a processor, implement the production process of the low-temperature-resistant rubber acoustic membrane as described above. The computer readable storage medium can be an internal storage unit of any data processing capable device, such as a hard disk or a memory. The computer readable storage medium can also be an external storage device, such as a plug-in hard disk, a smart media card (SMC), an SD card, a flash card, etc. Further, the computer readable storage medium can include both the internal storage unit and the external storage device of any data processing capable device. The computer readable storage medium is used to store the computer program and other programs and data required by the data processing capable device, and can also be used to temporarily store data that has been output or will be output.

[0057] Other embodiments of the present application will be apparent to those skilled in the art from consideration of the specification and practice of the application disclosed herein. It is intended that the present application cover any and all variations of the application that come within the scope of the general inventive concepts described herein and including all such variations that are within the scope of the appended claims.

[0058] It should be understood that the application is not limited to the precise construction that has been described above and shown in the accompanying drawings, and that various modifications and changes can be made by those skilled in the art without departing from the scope of the application.

Claims

1. A process for the production of a low temperature resistant rubber acoustic membrane, characterized in that, Comprising the following steps: Taking AEM as the base material, and through the steps of mixing, mixing, sheeting, coating, film forming and vulcanization, the basic preparation of low-temperature-resistant rubber acoustic film is completed; Divide the current low-temperature-resistant rubber acoustic film detection sub-area, obtain the detection data of each link of the sub-area for the same detection batch, and carry out detection link linkage to generate the comprehensive detection result of the detection sub-area; Based on the deviation level and source of the comprehensive detection result, dynamically adjust the parameter strategy.

2. The process for producing a low temperature resistant rubber acoustic membrane according to claim 1, wherein, In the step of taking AEM as the base material, and through the steps of mixing, mixing, sheeting, coating, film forming and vulcanization, the basic preparation of low-temperature-resistant rubber acoustic film is completed: A multi-stage raw material input method is used to prepare the mixed rubber; The raw material input method includes: the first stage of softening raw rubber, the second stage of mixing auxiliary agent, the third stage of adding reinforcing agent, and the fourth stage of adding vulcanization system; Adjust the roll gap of the open mill, use the open mill to prepare the open mill rubber sheet, melt the open mill rubber sheet to obtain the glue liquid, and then sequentially dry and vulcanize the glue liquid on the surface of the base material to obtain the film material.

3. The process for producing a low temperature resistant rubber acoustic membrane according to claim 2, wherein, After the step of adjusting the roll gap of the open mill, using the open mill to prepare the open mill rubber sheet, melting the open mill rubber sheet to obtain the glue liquid, and then sequentially drying and vulcanizing the glue liquid on the surface of the base material to obtain the film material: After the film material is naturally cooled to room temperature, it is wound to obtain the low-temperature-resistant rubber acoustic film basic product.

4. The process for producing a low temperature resistant rubber acoustic membrane according to claim 1, wherein, In the step of dividing the current low-temperature-resistant rubber acoustic film detection sub-area, obtaining the detection data of each link of the sub-area for the same detection batch, and carrying out detection link linkage to generate the comprehensive detection result of the detection sub-area: Collect the actual data of each sub-area corresponding to the detection index in time sequence; The collected data includes: low-temperature-resistant performance data, acoustic performance data, and mechanical performance data; Determine the influence weight of the detection index in each sub-area on the core performance; Combine the index standard degree and the influence weight to qualitatively determine the comprehensive result and locate the deviation source, and generate the comprehensive detection result of the detection sub-area.

5. The process for producing a cryogenically resistant rubber acoustic membrane according to claim 4, characterized in that, In the step of collecting the actual data of each sub-area corresponding to the detection index in time sequence; Before the step of collecting the actual data of each sub-area corresponding to the detection index in time sequence: Divide three independent detection sub-areas for the same production batch.

6. The process for producing a cryogenically resistant rubber acoustic membrane according to claim 5, characterized in that, In the step of collecting the actual data of each sub-area corresponding to the detection index in time sequence; In the step of collecting the actual data of each sub-area corresponding to the detection index in time sequence: Assign an identifier to the data collected for the same production batch.

7. The process for producing a cryogenically resistant rubber acoustic membrane according to claim 1, wherein, In the step of dynamically adjusting the parameter strategy based on the deviation level and source of the comprehensive detection result: According to the comprehensive detection result of the detection sub-area, adjust the production parameters for each sub-area respectively.

8. The process for producing a low temperature resistant rubber acoustic membrane according to claim 7, wherein, After the step of adjusting the production parameters for each sub-area respectively according to the comprehensive detection result of the detection sub-area: Obtain the production parameter adjustment data and use it in the next production batch.

9. The process for producing a cryogenically resistant rubber acoustic membrane according to claim 8, characterized in that, After the step of obtaining the production parameter adjustment data and using it in the next production batch: Detect the change of the subsequent raw material batch and update the current batch comprehensive detection result.

10. A production system of a low-temperature-resistant rubber acoustic membrane, applied to the production process of the low-temperature-resistant rubber acoustic membrane according to claim 1, characterized in that, The application relates to a low-temperature-resistant rubber acoustic film production system, comprising a rubber acoustic film preparation module, a detection step linkage module and a production parameter dynamic adjustment module. The rubber acoustic film preparation module is used for preparing a low-temperature-resistant rubber acoustic film by taking AEM as a base material and through mixing, sheeting, coating, film forming and vulcanization. The detection step linkage module is used for dividing a current low-temperature-resistant rubber acoustic film detection sub-region, acquiring detection data of each link of the sub-region for the same detection batch, carrying out linkage of the detection links and generating a comprehensive detection result of the detection sub-region. The production parameter dynamic adjustment module is used for dynamically adjusting a parameter strategy based on the deviation level and source of the comprehensive detection result.

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