Production equipment and method for vinyl toys

Abstract

The invention belongs to the technical field of vinyl forming, and discloses vinyl toy production equipment and method.The method comprises the steps that a heating plate on the inner wall of a raw material tank is started to heat raw materials, and a stirring mechanism is started to evenly mix the raw materials; the multi-cavity mold is fixed to an inner rotating ring of the turnover mechanism; the feeding mechanism injects raw materials in the raw material tank into a mold cavity; the turnover mechanism drives the mold to horizontally and vertically rotate synchronously; the taking and placing mechanism places products on the conveying belt assembly, and the conveying belt conveys the products into the primary cooling box, the secondary cooling box and the tertiary cooling box to complete gradient cooling. The image analysis module analyzes the image, and the comprehensive analysis module fuses the multi-source data, carries out comprehensive evaluation, and predicts the potential risk. The overturning mechanism drives the multi-cavity mold to synchronously rotate in the horizontal direction and the vertical direction, and bubbles are prevented from being generated when a vinyl raw material is formed; three-stage cooling of the vinyl toys is achieved through the three-stage gradient cooling system, and internal stress or deformation caused by too fast cooling of products is avoided.

Description

Technical Field

[0001] This application relates to the field of slush molding technology, and more specifically, to a slush toy manufacturing equipment and method. Background Technology

[0002] Slush molding is a process used to make toys. Liquid plastic material is poured into a mold, and then the mold is placed in a slush molding furnace for rotation and heating to form hollow or solid elastic products.

[0003] The prior art publication CN120245288A provides a molding equipment for producing slush toys, including a slush furnace. A placement rack is provided on the front side of the slush furnace, a drive assembly is fixedly provided on the outer wall of the rear side of the slush furnace, a rotating assembly is rotatably provided through the side wall of the furnace cavity, a connecting assembly is also fixedly provided on the outer wall of the rear side of the slush furnace, a precooling assembly is slidably provided on the placement rack, a support is placed on the precooling assembly, several molding assemblies are provided on the support, and a transmission assembly is provided at the bottom of the precooling assembly. This invention can immediately and automatically drive the connecting assembly and the rotating assembly to operate using steam pressure. This invention can also further improve the efficiency of uniform heat dissipation while ensuring that there is no sudden drop in temperature.

[0004] While the existing technical solutions described above can achieve the relevant beneficial effects through their structures, they still have the following drawbacks: 1. In existing technologies, mold rotation is mostly controlled by a single axis or simple dual axes asynchronously, resulting in uneven contact time between different areas of the mold and the raw material, which can easily lead to wall thickness deviations. 2. In traditional production, the molded product needs to be manually removed from the high-temperature molding chamber, which is not only cumbersome and time-consuming but also poses a risk of burns. 3. Existing technologies often employ single-stage or simple two-stage cooling, resulting in abrupt cooling transitions that can easily lead to surface shrinkage marks, edge warping, and other problems, especially for thin-walled or complex-shaped products, where deformation defects are more pronounced.

[0005] In view of this, we propose a production equipment and method for vinyl toys. Summary of the Invention

[0006] 1. The technical problems to be solved.

[0007] The purpose of this application is to provide a production equipment and method for slush toys, which solves the technical problems mentioned in the background art. It achieves the following technical effects: a flipping mechanism can drive a multi-cavity mold to rotate synchronously in both horizontal and vertical directions, avoiding air bubbles during slush material molding; a pick-and-place mechanism automatically picks up the molded slush toys, improving work efficiency; a three-stage gradient cooling system achieves three-stage cooling of the slush toys, preventing internal stress or deformation due to excessively rapid cooling; a multi-stage electric push rod of the feeding mechanism can precisely push the feeding nozzle to connect with the mold inlet, and the emulsifying pump can stably deliver raw materials; and the multi-cavity mold can simultaneously mold multiple products, significantly improving production efficiency.

[0008] 2. Technical solution.

[0009] This application provides a slush toy production equipment, including: a base, a raw material tank, a stirring mechanism, a constant temperature molding box, a flipping mechanism, a multi-cavity mold, a pick-and-place mechanism, a feeding mechanism, a primary cooling box, a secondary cooling box, a tertiary cooling box, and a conveyor belt assembly.

[0010] A thermostatic molding chamber is fixedly mounted on top of the base; a raw material tank is fixedly mounted on the right side of the thermostatic molding chamber, and a stirring mechanism is installed on the raw material tank. A tilting mechanism is rotatably mounted inside the thermostatic molding chamber via bearing seats. A multi-cavity mold is detachably fixedly mounted on the tilting mechanism. A feeding mechanism is fixedly mounted on one side of the raw material tank, and the feeding mechanism is interlocked with the multi-cavity mold.

[0011] The left side of the thermostatic molding chamber is equipped with a primary cooling chamber, a secondary cooling chamber, and a tertiary cooling chamber. The primary cooling chamber contains a pick-and-place mechanism for retrieving molded vinyl toy products. A conveyor belt assembly connects the primary, secondary, and tertiary cooling chambers, gradually transporting the vinyl toy products from the primary cooling chamber to the secondary and tertiary cooling chambers, thus achieving progressive cooling.

[0012] A high-temperature water tank, a medium-temperature water tank, and a low-temperature water tank are fixedly installed on top of the base; water pumps are installed inside the high-temperature, medium-temperature, and low-temperature water tanks; several nozzles are fixedly installed on the inner walls of the primary and secondary cooling tanks, and these nozzles are connected to the water pumps in the high-temperature and medium-temperature water tanks via pipelines. The output end of the water pump in the low-temperature water tank is located inside the tertiary cooling tank. A water collection tank is fixedly installed below the base, and the water collection tank is connected to the primary and secondary cooling tanks.

[0013] As an optional embodiment of the present invention, the stirring mechanism includes a motor A, a rotating shaft, a scraper, a ring, an outer stirring blade, and an inner stirring blade.

[0014] A detachable lid is fixedly mounted on the raw material tank. A motor A is fixedly mounted above the lid, and a rotating shaft is coaxially fixed to the output end of motor A. A scraper blade is fixedly mounted on the rotating shaft; the scraper blade has a rectangular structure and contacts the inner wall of the raw material tank. A dual-shaft motor is fixedly mounted on the rotating shaft, and a connecting rod is fixedly mounted to the output end of the dual-shaft motor. Multiple inner stirring blades are mounted on the connecting rod, and a circular ring is fixedly mounted on the outer side of the connecting rod, with several outer stirring blades evenly distributed on the ring. A heating plate and a temperature sensor are fixedly mounted on the inner wall of the raw material tank.

[0015] As an optional embodiment of the present invention, the flipping mechanism includes an outer rotating ring, an outer shaft, an inner rotating ring, gear A, and a mold opening mechanism.

[0016] A speed-regulating motor is fixedly installed below the base, and outer shafts are fixedly installed at both ends of the outer rotating ring; the outer shafts are coaxially and fixedly connected to the output end of the speed-regulating motor. Furthermore, the outer shafts are fixedly connected to the output end of the speed-regulating motor via a coupling.

[0017] The outer rotating ring has two rotatable gear shafts; an inner rotating ring is detachably fixed between the two gear shafts; a multi-cavity mold is detachably fixed on the inner rotating ring. An opening mechanism is fixedly mounted on the inner rotating ring. The two gear shafts are symmetrically arranged, and their inner sides are detachably fixed to the inner rotating ring via bolts.

[0018] The multi-cavity mold includes a moving platen and a fixed platen. The fixed platen is detachably fixed on the inner rotating ring, while the moving platen is slidably mounted on the inner rotating ring. The moving platen is detachably fixedly connected to the mold opening mechanism, which can move the moving platen. Multiple cavities are provided within the moving and fixed platens, and the moving and fixed platens are engaged to form a complete mold. Multiple feed ports are provided on the fixed platen. The feed ports are movably connected to the feeding mechanism. Angle sensors and wireless signal transmission modules are installed on both the outer and inner rotating rings.

[0019] A gear ring is fixedly installed inside the base. Gear A is coaxially fixed to the outer end of the gear shaft, and gear A meshes with the gear ring for transmission. Venting grooves are provided on the inner wall of the cavity to prevent air bubbles from forming during molding.

[0020] The above technical solution involves starting a speed-regulating motor to drive the outer rotating ring, inner rotating ring, and multi-cavity mold to rotate horizontally. As the outer rotating ring rotates, it drives gear A to rotate. Gear A meshes with the gear ring, causing gear A to rotate on its own axis. Gear A then drives the inner rotating ring to rotate vertically, thus achieving synchronous rotation of the multi-cavity mold in both the horizontal and vertical directions, resulting in more uniform molding of the PVC toy.

[0021] This invention provides a method for producing vinyl toys, comprising the following steps.

[0022] S1. Pour the enamel material into the raw material tank and tighten the lid. Activate the heating plate on the inner wall of the raw material tank, and in conjunction with the temperature sensor, heat the raw material to the process set temperature. Start the stirring mechanism to achieve uniform mixing of the raw material.

[0023] S2. Mold Installation and Preheating: Fix the multi-cavity mold on the inner rotating ring of the flipping mechanism, align the feed port of the fixed mold plate with the direction of the feeding mechanism, and ensure smooth venting through the venting grooves on the inner wall of the mold cavity. Start the annular heating pipe and hot air circulation system of the constant temperature molding chamber to preheat the mold to the molding temperature.

[0024] S3, Raw Material Injection: The multi-stage electric actuator of the feeding mechanism pushes the feeding nozzle to open the heat insulation baffle of the thermostatic molding box and inserts it into the feed port of the fixed template. The emulsification pump is started to inject the uniform raw material in the raw material tank into the mold cavity through the feeding nozzle.

[0025] S4. Flipping and Molding: After feeding is completed, the feeding nozzle retracts, the heat insulation baffle is reset under the action of the reset spring, the constant temperature molding box maintains a constant temperature, and the flipping mechanism drives the mold to rotate horizontally and vertically synchronously to ensure that the slush material is evenly distributed in the cavity and avoids air bubbles and uneven molding.

[0026] S5. Mold Opening and Part Removal: After molding, the flipping mechanism rotates the mold to a horizontal part removal position. The feeding mechanism connects the nozzle to the air inlet, and the high-pressure air pump supplies air to the multi-stage telescopic cylinder of the mold opening mechanism through a rotary joint, pushing the moving platen open. Motor B of the sealing door assembly is activated, causing the sealing door to rise and open the rectangular opening. The pick-and-place mechanism adjusts its position via multi-stage electric telescopic rods A and B, and the pneumatic suction cup adsorbs the molded product. The vision positioning module corrects the position. Then, the mold opening mechanism closes the mold, the pick-and-place mechanism resets, the sealing door closes, and the flipping mechanism returns to the feeding position.

[0027] S6. Gradient Cooling: The pick-and-place mechanism places the product on the conveyor belt assembly, and the conveyor belt sequentially sends the product into the primary cooling box, the secondary cooling box, and the tertiary cooling box to complete the gradient cooling.

[0028] S7, the monitoring agency's image acquisition module acquires high-definition images of the vinyl toy production process. The data acquisition module acquires temperature and humidity data.

[0029] S8, the image analysis module analyzes the acquired images and promptly detects anomalies.

[0030] S9. The comprehensive analysis module integrates the monitoring results from the image acquisition module, data acquisition module, and image analysis module, combines them with historical data, conducts a comprehensive assessment, and predicts potential risks.

[0031] S10. When an abnormal situation or potential risk is detected, the alarm module issues an alarm.

[0032] 3. Beneficial effects.

[0033] One or more technical solutions provided in this application have at least the following technical effects or advantages.

[0034] 1. The flipping mechanism of the present invention can drive the multi-cavity mold to rotate synchronously in the horizontal and vertical directions. In conjunction with the venting groove of the mold cavity, it can prevent air bubbles from being generated during the molding of slush material. The constant temperature molding box, through the combination of annular heating pipe and hot air circulation, can prevent molding defects caused by local overheating and ensure the regularity of product shape.

[0035] 2. The molded PVC toys are automatically picked up by the pick-and-place mechanism, improving work efficiency.

[0036] 3. Stable cooling and deformation prevention: The three-stage gradient cooling system achieves three-stage cooling of the vinyl toys, avoiding internal stress or deformation caused by excessively rapid cooling.

[0037] 4. The multi-stage electric actuator of the feeding mechanism can accurately push the feeding nozzle to connect with the mold inlet, and the emulsification pump can stably deliver raw materials; the pick-and-place mechanism (or SCARA type robot) is equipped with a vision positioning module to quickly complete the picking of parts. The various mechanisms are coordinated in sequence through the PLC control module, which greatly shortens the process interval.

[0038] 5. Multi-cavity molds can mold multiple products simultaneously, and with multiple feeding nozzles of the feeding mechanism, material is injected synchronously. Compared with single-cavity molds, production efficiency is significantly improved, and it is suitable for multi-batch production needs.

[0039] 6. From raw material mixing and feeding to molding, mold opening and part removal, and gradient cooling, the entire process is automatically operated by the PLC control module, which links all mechanisms without frequent manual intervention. This avoids human error and increases output per unit time.

[0040] 7. The scraper of the mixing mechanism can scrape off the raw material adhering to the inner wall of the raw material tank to avoid material waste; the flow meter and solenoid valve of the feeding mechanism can accurately control the feeding amount to prevent excessive injection of raw material and loss. Attached Figure Description

[0041] Figure 1 This is an overall schematic diagram of a vinyl toy production equipment disclosed in a preferred embodiment of this application.

[0042] Figure 2 This is a schematic diagram of the internal structure of a vinyl toy production equipment disclosed in a preferred embodiment of this application.

[0043] Figure 3 This is a schematic diagram of the stirring mechanism of a vinyl toy production equipment disclosed in a preferred embodiment of this application.

[0044] Figure 4 This is a schematic diagram of the flipping mechanism of a vinyl toy production equipment disclosed in a preferred embodiment of this application.

[0045] Figure 5 This is a schematic diagram of the multi-cavity mold of a vinyl toy production equipment in the open state, as disclosed in a preferred embodiment of this application.

[0046] Attached reference numerals: 1. Base; 2. Raw material tank; 3. Stirring mechanism; 4. Constant temperature molding chamber; 5. Tilting mechanism; 6. Multi-cavity mold; 7. Picking and placing mechanism; 8. Feeding mechanism; 9. Sealing door assembly; 10. Primary cooling tank; 11. Secondary cooling tank; 12. Tertiary cooling tank; 13. Conveyor belt assembly; 131. Side baffle; 14. Water collection tank; 15. High temperature water tank; 16. Medium temperature water tank; 17. Low temperature water tank; 21. Tank lid;

[0047] 31. Motor A; 32. Rotating shaft; 33. Scraper; 34. Ring; 35. Outer stirring blade; 36. Connecting rod; 37. Inner stirring blade; 41. Gear ring; 42. Heat insulation baffle; 43. Rectangular opening; 51. Outer rotating ring; 52. Outer shaft; 53. Inner rotating ring; 54. Gear A; 55. Mold opening mechanism; 551. Multi-stage telescopic cylinder; 552. Fixing plate; 56. Gear shaft; 61. Moving template; 62. Fixed template; 63. Feed inlet; 64. Cavity; 71. Multi-stage electric telescopic rod A; 72. Multi-stage electric telescopic rod B; 73. Positioning plate; 74. Pneumatic suction cup; 81. Emulsifying pump; 82. Multi-stage electric push rod; 83. Feed nozzle; 91. Motor B; 92. Gear B; 93. Sealing door; 931. Gear groove. Detailed Implementation

[0048] The present application will be further described in detail below with reference to the accompanying drawings.

[0049] Reference Figure 1 and Figure 2 This application provides a vinyl toy production equipment, including: a base 1, a raw material tank 2, a stirring mechanism 3, a constant temperature molding box 4, a flipping mechanism 5, a multi-cavity mold 6, a pick-and-place mechanism 7, a feeding mechanism 8, a primary cooling box 10, a secondary cooling box 11, a tertiary cooling box 12, and a conveyor belt assembly 13.

[0050] A constant temperature forming chamber 4 is fixedly mounted on top of the base 1. A raw material tank 2 is fixedly mounted on the right side of the constant temperature forming chamber 4, and a stirring mechanism 3 is mounted on the raw material tank 2. A tilting mechanism 5 is rotatably mounted inside the constant temperature forming chamber 4 via a bearing seat. A multi-cavity mold 6 is detachably fixedly mounted on the tilting mechanism 5. A feeding mechanism 8 is fixedly mounted on one side of the raw material tank 2, and the feeding mechanism 8 is inserted and engaged with the multi-cavity mold 6. The base 1 is welded from Q235 steel plate, and shock-absorbing pads are installed at the bottom to reduce vibration and noise during equipment operation. The raw material tank 2 is made of 304 stainless steel.

[0051] On the left side of the constant temperature molding chamber 4, a primary cooling chamber 10, a secondary cooling chamber 11, and a tertiary cooling chamber 12 are arranged sequentially. The primary cooling chamber 10 is equipped with a pick-and-place mechanism 7, which is used to pick up the molded slush-molded toy products. A conveyor belt assembly 13 is arranged between the primary cooling chamber 10, the secondary cooling chamber 11, and the tertiary cooling chamber 12. The conveyor belt assembly 13 is used to gradually transport the slush-molded toy products from the primary cooling chamber 10 to the secondary cooling chamber 11 and the tertiary cooling chamber 12, thereby achieving gradual cooling of the slush-molded toy products.

[0052] A high-temperature water tank 15, a medium-temperature water tank 16, and a low-temperature water tank 17 are fixedly installed above the base 1. Water pumps are installed inside each of these tanks. Several nozzles are fixedly installed on the inner walls of the primary cooling tank 10 and the secondary cooling tank 11. These nozzles are connected to the water pumps in the high-temperature water tank 15 and the medium-temperature water tank 16 via pipes. The output end of the water pump in the low-temperature water tank 17 is located inside the tertiary cooling tank 12 to replenish the tertiary cooling tank 12 with cooling water.

[0053] A water collection tank 14 is fixedly installed below the base 1. The water collection tank 14 is connected to the primary cooling tank 10 and the secondary cooling tank 11 to collect the water that falls and recycle it.

[0054] In this technical solution, the three-stage cooling tank 12 contains cold water; the raw material tank 2 contains slush molding material, which is stirred evenly by the stirring mechanism 3. The slush molding material in the raw material tank 2 is injected into the multi-cavity mold 6 by the feeding mechanism 8. Then, the slush molding material in the multi-cavity mold 6 is formed into a slush molding toy by the constant temperature molding box 4; the flipping mechanism 5 drives the multi-cavity mold 6 to rotate horizontally and vertically, so that the slush molding toy is formed evenly. After molding, the toy in the multi-cavity mold 6 is taken out by the pick-and-place mechanism 7 and placed on the conveyor belt assembly 13, and then the slush molding toy is gradually cooled by the primary cooling tank 10, the secondary cooling tank 11, and the tertiary cooling tank 12.

[0055] Reference Figure 1 and Figure 3 The stirring mechanism 3 includes a motor A31, a rotating shaft 32, a scraper 33, a ring 34, an outer stirring blade 35, and an inner stirring blade 37.

[0056] A detachable lid 21 is fixedly mounted on the raw material tank 2. A motor A31 is fixedly mounted above the lid 21, and a rotating shaft 32 is coaxially fixedly mounted on the output end of the motor A31. A scraper 33 is fixedly mounted on the rotating shaft 32. The scraper 33 has a rectangular structure and is positioned in contact with the inner wall of the raw material tank 2 to scrape off the raw material adhering to the inner wall of the raw material tank 2. A silicone sealing ring with a sealing rating of IP65 is provided on the lid 21. A dual-shaft motor is fixedly mounted on the rotating shaft 32, and a connecting rod 36 is fixedly mounted on the output end of the dual-shaft motor. Multiple inner stirring blades 37 are mounted on the connecting rod 36, and a circular ring 34 is fixedly mounted on the outer side of the connecting rod 36. Several outer stirring blades 35 are evenly distributed on the circular ring 34.

[0057] A heating plate and a temperature sensor are fixedly installed on the inner wall of the raw material tank 2. The heating plate heats the slush material, and the temperature sensor controls the heating temperature of the slush material.

[0058] In this technical solution, the enamel raw material is heated by a heating plate. Motor A31 is started, driving the rotating shaft 32 and the scraper 33 to rotate. The scraper 33 is positioned in contact with the inner wall of the raw material tank 2, scraping away the raw material adhering to the inner wall. The rotating shaft 32 drives the outer stirring blade 35 and the inner stirring blade 37 to revolve, while the dual-shaft motor drives the outer stirring blade 35 and the inner stirring blade 37 to rotate on their own axes, making the raw material in the raw material tank 2 more evenly mixed.

[0059] Reference Figure 1 , Figure 4 and Figure 5 The flipping mechanism 5 includes an outer rotating ring 51, an outer shaft 52, an inner rotating ring 53, a gear A 54, and a mold opening mechanism 55.

[0060] A speed-regulating motor is fixedly installed below the base 1, and outer shafts 52 are fixedly installed at the upper and lower ends of the outer rotating ring 51; the outer shafts 52 are coaxially and fixedly connected to the output end of the speed-regulating motor. Furthermore, the outer shafts 52 are fixedly connected to the output end of the speed-regulating motor through a coupling.

[0061] Two gear shafts 56 are rotatably mounted on the outer rotating ring 51; an inner rotating ring 53 is detachably fixed between the two gear shafts 56; a multi-cavity mold 6 is detachably fixed on the inner rotating ring 53. A mold opening mechanism 55 is fixedly mounted on the inner rotating ring 53. The two gear shafts 56 are symmetrically arranged, and their inner sides are detachably fixed to the inner rotating ring 53 by bolts.

[0062] The multi-cavity mold 6 includes a movable template 61 and a fixed template 62. The fixed template 62 is detachably fixed on the inner rotating ring 53, and the movable template 61 is slidably mounted on the inner rotating ring 53. The movable template 61 is detachably fixedly connected to the mold opening mechanism 55. The mold opening mechanism 55 can drive the movable template 61 to move.

[0063] Multiple cavities 64 are provided within the moving template 61 and the fixed template 62. When the moving template 61 and the fixed template 62 are engaged, a complete mold is formed. Multiple feed inlets 63 are provided on the fixed template 62. The feed inlets 63 are movably connected to the feeding mechanism 8. Angle sensors and wireless signal transmission modules are provided on both the outer rotating ring 51 and the inner rotating ring 53.

[0064] A gear ring 41 is fixedly installed inside the base 1. A gear A54 is coaxially fixedly installed at the outer end of the gear shaft 56, and the gear A54 meshes with the gear ring 41 for transmission.

[0065] The inner wall of the cavity 64 is provided with 0.5mm wide venting grooves (spaced 10.0mm) to prevent air bubbles from forming during molding. A silicone sealing ring (Shore hardness 50°) is installed inside the feed inlet 63 on the fixed mold plate 62. The feed inlet 63 is movably connected to the feed nozzle 83 of the feeding mechanism 8 to ensure no leakage of raw material during injection. A PT100 temperature sensor is also embedded inside the mold to monitor the cavity temperature in real time and provide feedback to the PLC for precise temperature control. A one-way valve is installed inside the feed inlet 63.

[0066] The main body of the moving template 61 and the fixed template 62 is made of Cr12MoV high-strength wear-resistant alloy steel and is vacuum quenched (hardness reaches HRC58-62) to ensure that the service life of the mold exceeds 100,000 cycles; the surface of the cavity adopts nano-level polishing and chrome plating process, with roughness Ra≤0.02μm, which greatly reduces the adhesion of slush material and improves the surface smoothness of the product.

[0067] In this technical solution, a speed-regulating motor is started to drive the outer rotating ring 51, the inner rotating ring 53, and the multi-cavity mold 6 to rotate horizontally. When the outer rotating ring 51 rotates, it drives the gear A54 to rotate. The gear A54 meshes with the gear ring 41, causing the gear A54 to rotate on its own axis. The gear A54 then drives the inner rotating ring 53 to rotate vertically, thereby achieving synchronous rotation of the multi-cavity mold 6 in both the horizontal and vertical directions, resulting in more uniform molding of the PVC toy.

[0068] Furthermore, the mold opening mechanism 55 includes a multi-stage telescopic cylinder 551 and a fixed plate 552.

[0069] Two multi-stage telescopic cylinders 551 are fixedly installed on the inner rotating ring 53. A fixing plate 552 is fixedly installed on the end movable rod of the multi-stage telescopic cylinder 551. The fixing plate 552 is detachably fixedly connected to the moving template 61 by a number of stainless steel bolts.

[0070] In this technical solution, two multi-stage telescopic cylinders 551 drive the moving template 61 to move, thereby achieving the locking and unlocking of the moving template 61.

[0071] Reference Figure 1 and Figure 2The pick-and-place mechanism 7 includes a multi-stage electric telescopic rod A71, a multi-stage electric telescopic rod B72, a positioning plate 73, and a pneumatic suction cup 74.

[0072] A multi-stage electric telescopic rod A71 is fixedly installed on the primary cooling box 10. A multi-stage electric telescopic rod B72 is fixedly installed on the final movable rod of the multi-stage electric telescopic rod A71. A positioning plate 73 is fixedly installed on the final movable rod of the multi-stage electric telescopic rod B72. A pneumatic suction cup 74 is fixedly installed on the positioning plate 73. The multi-stage electric telescopic rods A71 and B72 are vertically arranged. An air pump is fixedly installed on the primary cooling box 10, and the air pump is connected to the pneumatic suction cup 74 through a pipeline. The pneumatic suction cup 74 is a vacuum suction cup made of silicone material, which increases the contact area between the suction cup and the surface of the toy and reduces the pressure per unit area; at the same time, micro-ventilation holes are set on the surface of the suction cup to reduce negative pressure marks during suction and ensure the surface smoothness of the product.

[0073] A sealing door assembly 9 is provided on the primary cooling chamber 10; the sealing door assembly 9 includes a motor B91, a gear B92, and a sealing door 93. The motor B91 is fixedly mounted on the left side of the primary cooling chamber 10, and the gear B92 is coaxially fixedly mounted on the output end of the motor B91; the sealing door 93 is slidably mounted on the left side wall of the primary cooling chamber 10, and the sealing door 93 has several toothed grooves 931. The toothed grooves 931 mesh with the gear B92 for transmission. A rectangular opening 43 is provided on the left side of the primary cooling chamber 10. The loading / unloading mechanism 7 can retrieve the molded vinyl toy through the rectangular opening 43.

[0074] In this technical solution, the starter motor B91 drives the gear B92 to rotate, and the gear B92 drives the sealing door 93 to move up and down, thereby opening and closing the rectangular opening 43.

[0075] In this technical solution, the pneumatic suction cup 74 is moved up and down by the multi-stage electric telescopic rod A71, and the pneumatic suction cup 74 is moved back and forth by the multi-stage electric telescopic rod B72, so that the PVC toys can be picked up and put down by the pneumatic suction cup 74.

[0076] Furthermore, the feeding mechanism 8 includes an emulsifying pump 81, a multi-stage electric actuator 82, and a feeding nozzle 83;

[0077] Multiple emulsifying pumps 81 (model JRJ300-S, power 750W, flow rate 0-10L / min, pressure 0.3MPa) are fixedly mounted on the base 1. Multi-stage electric actuators 82 are fixedly mounted on the base 1 via an L-shaped plate. Multiple feeding nozzles 83 are fixedly mounted on the final movable rod of each multi-stage electric actuator 82. The feeding nozzles 83 are connected to the output ends of their respective emulsifying pumps 81 via pipelines. The input end of the emulsifying pump 81 extends into the raw material tank 2. A flow meter and a solenoid valve are installed at the rear end of each feeding nozzle 83.

[0078] The feeding nozzle 83 is movably connected to the inlet 63 on the multi-cavity mold 6.

[0079] An air inlet is provided on the inner rotating ring 53, and a high-pressure air pump is fixedly mounted on the base 1. The output end of the high-pressure air pump is connected to a connector (model DMSX-10, temperature resistant 150℃) and a pipeline via a rotary joint. The connector is fixedly mounted on the final movable rod of the multi-stage electric actuator 82, and the connector is movably inserted into the air inlet. The air inlet is connected to the multi-stage telescopic cylinder 551 via a pipeline.

[0080] In this technical solution, when the multi-cavity mold 6 rotates to a vertical position and is perpendicular to the feeding nozzle 83, the multi-stage electric actuator 82 drives the feeding nozzle 83 to move to the multi-cavity mold 6 and insert it into the inlet 63. The emulsifying pump 81 then injects the enamel material from the raw material tank 2 into the cavity 64 of the multi-cavity mold 6. High-pressure gas is injected into the multi-stage telescopic cylinder 551 via a high-pressure air pump. The multi-stage telescopic cylinder 551 drives the moving template 61 to move, thus opening and closing the mold. The emulsifying pump 81 adopts a rotor-stator structure, which performs secondary shearing and mixing of the raw material during the feeding process, further improving the uniformity of the raw material.

[0081] Furthermore, the constant temperature molding chamber 4 is provided with a square hole, and a heat insulation baffle 42 is rotatably provided at the square hole. A return spring is provided on the heat insulation baffle 42, and the other end of the return spring is fixedly provided on the constant temperature molding chamber 4.

[0082] In this technical solution, the square hole allows the feeding nozzle 83 to pass through. When the feeding nozzle 83 moves forward, it can push open the heat insulation baffle 42, allowing the feeding nozzle 83 to enter the constant temperature forming chamber 4 to feed the multi-cavity mold 6. When the feeding nozzle 83 exits the constant temperature forming chamber 4, the heat insulation baffle 42 automatically resets under the action of the return spring.

[0083] Furthermore, a conveyor belt assembly 13 is installed between the primary cooling tank 10, the secondary cooling tank 11, and the tertiary cooling tank 12 via flange connections. The conveyor belt assembly 13 uses a food-grade PU conveyor belt to gradually transport the vinyl toy products from the primary cooling tank 10 to the secondary cooling tank 11 and the tertiary cooling tank 12, achieving gradient cooling. A drain outlet is provided at the bottom of the tertiary cooling tank 12, which is connected to the return water outlet of the low-temperature water tank 17 via a pipeline. A small stirring paddle (driven by a waterproof motor) is installed inside the tertiary cooling tank 12 to ensure uniform water temperature within the tank. A water temperature sensor is installed in the tertiary cooling tank 12, which is linked to the water pump in the low-temperature water tank 17: when the water temperature in the tank is >15.0℃, the water pump automatically replenishes water; when the water temperature is <5.0℃, the water pump stops replenishing water, maintaining the water temperature within the range of 5.0-15.0℃.

[0084] Furthermore, heaters are fixedly installed on the inner walls of both the high-temperature water tank 15 and the medium-temperature water tank 16; the high-temperature water tank 15 is temperature-controlled at 60-70℃, the medium-temperature water tank 16 at 30-40℃, and the low-temperature water tank 17 at 5-15℃. Each of the three tanks is equipped with a stainless steel centrifugal pump (model ISG50-160). Several atomizing nozzles (model 1 / 4JAC, spray angle 90°) are fixedly installed on the inner walls of the primary cooling tank 10 and the secondary cooling tank 11. The nozzles in the primary cooling tank 10 are connected to the water pump in the high-temperature water tank 15 via pipelines, and the nozzles in the secondary cooling tank 11 are connected to the water pump in the medium-temperature water tank 16. The output end of the water pump in the low-temperature water tank 17 extends into the tertiary cooling tank 12 via a coil, replenishing the tertiary cooling tank 12 with cold water and forming a circulation. The water collection tank 14 is connected to the bottom drain of the primary cooling tank 10 and the secondary cooling tank 11 through the return water pipe to collect the falling cooling water. The water collection tank 14 is equipped with a filter cotton core and a water level sensor to realize the filtration and recycling of cooling water.

[0085] Furthermore, a heating element is installed inside the thermostatic molding chamber 4.

[0086] The heating element employs a combination of ring-shaped heating tubes and hot air circulation. Eight sets of stainless steel heating tubes (1.5kW / set, temperature resistance 200℃) are evenly arranged circumferentially on the inner wall of the constant temperature forming chamber 4, in conjunction with a high-temperature axial fan (10m³ / h) at the top of the chamber. 3 / min (high temperature resistance), forming a forced hot air circulation, so that the temperature uniformity inside the chamber is controlled within ±3.0℃, which meets the requirements of slush molding.

[0087] Four PT100 temperature sensors are symmetrically installed inside the molding chamber to provide real-time temperature feedback for different areas. The PLC control module dynamically adjusts the power of each heating element to prevent localized overheating. A ceramic fiber heat insulation sleeve is installed at the connection between the outer shaft 52 of the flipping mechanism 5 and the side wall of the molding chamber to prevent heat from the molding chamber from being conducted to the external bearing housing through the shaft, ensuring that the bearing operating temperature is ≤60℃.

[0088] The power cord of the heating element of the constant temperature molding chamber 4 can be directly led out from the wire hole (with high temperature resistant sealing ring) reserved on the side wall and connected to the external temperature control cabinet, completely avoiding the problem of wire tangling.

[0089] Furthermore, the pick-and-place mechanism 7 is replaced with a multi-degree-of-freedom robotic arm: a SCARA-type industrial robotic arm (such as EPSON LS3-401S) is selected, with a load capacity of 1.5kg, a repeatability of ±0.03mm, and an upgraded IP67 protection rating, suitable for high-temperature and water mist environments. The multi-degree-of-freedom robotic arm is equipped with an adaptive multi-suction cup end effector, a vision positioning module, and an air curtain protection device.

[0090] Adaptive multi-suction cup end effector: includes mounting plate and suction cups.

[0091] The mounting plate is made of 6061 aluminum alloy with an anodized surface; the mounting plate is fixedly installed at the end of the robotic arm.

[0092] The number of suction cups is the same as the number of cavities in the multi-cavity mold 6. Each suction cup is made of high-temperature resistant silicone and is connected to the mounting plate via an M3 elastic telescopic rod.

[0093] Each suction cup is equipped with a miniature vacuum pressure sensor (model MPX5700DP, measuring range 0-10kPa), which is connected to the PLC control module via a signal cable. The PLC control module presets the pressure threshold according to the product weight.

[0094] Air curtain protection device: A ring-shaped air passage is set at the base and joints of the robot, and the air passage is connected to the high-pressure air pump of the equipment; a ring-shaped nozzle (nozzle diameter 0.5mm, spray angle 360°) is set at the outlet of the air passage, which sprays high-pressure airflow to form an air curtain during operation to block water mist intrusion; a condensate collection tank is set at the bottom of the robot body, and the collection tank is connected to the water collection tank 14 through a drain pipe to realize the recycling of condensate.

[0095] The vision positioning module uses an industrial camera (Basler acA1300-200uc) mounted on the side of the robot's end effector plate. The lens is waterproof and dustproof (IP67 protection rating). The image recognition algorithm uses the OpenCV open-source library, identifying the edge contours of each cavity product through template matching, calculating the offset, and sending the offset data to the robot controller to dynamically adjust the motion trajectory. The robot controller communicates with the equipment's PLC control module via the Profinet protocol to achieve the following timing coordination: the mold opening mechanism 55 drives the template 61 to open, and the magnetostrictive displacement sensor detects the mold opening position signal; the PLC sends a material handling command to the robot, the vision positioning module starts, and corrects the material handling position; the robot extends into the mold, the adaptive multi-suction cup end effector starts, and the miniature pressure sensor reports that the suction pressure is within the specified range; the robot moves the product out of the mold, through the rectangular opening 43 into the primary cooling box 10, and places the product on the conveyor belt assembly 13; the conveyor belt assembly 13 starts, transporting the product to the secondary cooling box 11, the robot resets, and waits for the next material handling command.

[0096] Furthermore, a conical guide sleeve with a taper of 15.0° is provided at the feed inlet 63 of the fixed template 62. The guide sleeve is made of wear-resistant copper and has an embedded silicone sealing ring. The front end of the feeding nozzle 83 is machined into a matching conical head to achieve precise insertion with the guide sleeve. Even if there is a positioning deviation of ±0.5mm in the mold, it can be corrected by the conical guide. A pressure sensor is installed at the end of the feeding nozzle 83. When the insertion pressure reaches the preset value, it is determined that the insertion is in place, and the emulsification pump is started to inject material.

[0097] Furthermore, a synchronization valve (such as Festo MS6-SV) is installed at the air inlet of the two multi-stage telescopic cylinders 551 to ensure that the air inlet pressure and flow of the two cylinders are completely synchronized; linear guides and displacement sensors are installed on both sides of the moving template 61 to provide real-time feedback on the displacement deviation of the moving template. When the deviation on both sides is >0.1mm, the PLC control module automatically adjusts the air inlet flow of the corresponding cylinder to correct the deviation; the connecting bolts between the fixing plate 552 of the mold opening mechanism 55 and the moving template 61 are made of elastic buffer pads to absorb the impact force when the cylinder starts and stops, and prevent the moving template from tilting.

[0098] Furthermore, a monitoring mechanism is installed on the base 1 to monitor and adjust the production process of vinyl toys. The monitoring mechanism includes...

[0099] Data collection module: Collects data on vinyl toy production equipment, production process data and design data of vinyl toys, collects historical data, and annotates the data as a reference sample.

[0100] Image acquisition module: Includes a high-definition camera to capture high-definition images of the vinyl toy production process.

[0101] Data acquisition module: Includes temperature and humidity sensors, etc., to collect temperature and humidity data.

[0102] Image analysis module: Analyzes the acquired images to detect anomalies in a timely manner.

[0103] Comprehensive Analysis Module: This module integrates the monitoring results from the image acquisition module, data acquisition module, and image analysis module, combines them with historical data, conducts a comprehensive assessment, and predicts potential risks.

[0104] Based on the comprehensive data of the viscosity and feed rate of the slush material, the rotation speed of the flipping mechanism 5, the temperature inside the constant temperature molding box 4, the water spray temperature, water volume and duration of the primary cooling box 10, the water spray temperature, water volume and duration of the secondary cooling box 11, and the water temperature and duration of the tertiary cooling box 12 during the production process, a comprehensive evaluation model is established to conduct a comprehensive evaluation and predict potential risks.

[0105] Alarm module: Includes an alarm that sounds when an abnormal situation or potential risk is detected.

[0106] PLC control module: This is a programmable control module that is network-connected to data collection module, image acquisition module, image analysis module, comprehensive analysis module, alarm module, stirring mechanism 3, tilting mechanism 5, picking and placing mechanism 7, feeding mechanism 8, sealing door assembly 9, conveyor belt assembly 13, etc.

[0107] Furthermore, the data acquisition module includes...

[0108] Viscosity online monitoring component: A capillary viscosity sensor is connected in series in the outlet pipeline of raw material tank 2 to collect dynamic viscosity data of enamel raw material in real time.

[0109] Raw material uniformity monitoring component: A miniature ultrasonic sensor is set at the front end of the feed nozzle 83 to detect tiny particle agglomerates in the raw material by measuring the ultrasonic attenuation, and to provide real-time feedback on the uniformity of raw material mixing; in conjunction with the flow meter at the rear end of the emulsification pump 81, the correlation data between the raw material delivery flow rate and uniformity is collected synchronously.

[0110] Multi-parameter synchronous acquisition component for mold: Three sets of PT100 temperature sensors and two sets of pressure sensors (model Kistler 6157B, measurement range 0-10MPa) are embedded in the moving platen 61 and fixed platen 62 of the multi-cavity mold 6 to collect the temperature distribution and molding pressure of each cavity 64 in real time; based on the angle sensors of the outer rotating ring 51 and the inner rotating ring 53, an angular velocity sensor is added to collect the horizontal and vertical rotation acceleration of the flipping mechanism 5 and provide feedback on the stability of the mold rotation.

[0111] Cavity venting status acquisition component: A miniature gas flow sensor (model FS4002) is installed at the venting outlet of the mold to determine the venting status of air bubbles in cavity 64 by the change of venting flow; when the venting flow is lower than the preset threshold, it is determined that the venting is not smooth and an adjustment command is triggered in time.

[0112] Gradient cooling parameter acquisition components: Multi-point temperature and humidity sensors are installed in the primary cooling tank 10 and the secondary cooling tank 11 to synchronously collect the temperature and humidity distribution in the cooling tank; a miniature contact temperature sensor is embedded in the conveyor belt of the conveyor belt assembly 13 to collect the surface temperature of the PVC toy in each cooling stage in real time; a water level sensor and a water temperature sensor are installed in the tertiary cooling tank 12 to monitor the cold water level in real time.

[0113] Power component monitoring assembly: Vibration sensors (model SDM-200) and current sensors (model ACS712) are installed on the motor A31 of the stirring mechanism 3, the speed regulating motor of the tilting mechanism 5, the emulsifying pump 81 of the feeding mechanism 8, and the servo motor of the multi-degree-of-freedom manipulator, respectively, to collect the vibration amplitude and current fluctuation of the motor in real time and determine the stability of the equipment operation.

[0114] Furthermore, the image analysis module analyzes the acquired images, including the following steps.

[0115] 1. Image Input and Preprocessing: Remove noise, water vapor, uneven lighting, and other interfering factors from the image, and standardize the image format. This includes image format unification, noise suppression, region of interest extraction, and uneven lighting correction.

[0116] Unified image format: Receives high-definition images transmitted from the multi-station image acquisition module, converts color images to grayscale images, reduces data processing volume, and retains key defect information.

[0117] Noise suppression: To address image blurring caused by water vapor inside the cooling tank, a bilateral filtering algorithm is used for noise reduction, preserving defect edge details while removing noise. For the salt-and-pepper noise inherent in the industrial camera sensor, a median filtering algorithm is applied with a 3×3 filter window to eliminate isolated noise points.

[0118] Illumination unevenness correction: Adaptive histogram equalization (CLAHE) algorithm is used to process the image into blocks and limit the contrast threshold to 2.0 to avoid missing defects caused by local over-brightness or under-brightness; the corrected image is normalized to map the pixel gray values ​​to the range of 0-255 to ensure that images acquired under different lighting conditions are comparable.

[0119] Region of Interest (ROI) extraction: A threshold segmentation algorithm (Otsu adaptive thresholding) is used to automatically calculate the optimal segmentation threshold, dividing the image into foreground (molde toy area) and background (mold cavity / conveyor belt area); based on the preset product standard outline (toy shape template imported from CAD drawings), a template matching algorithm (normalized cross-correlation coefficient NCC ≥ 0.9) is used to locate the foreground region, extract the ROI, and eliminate background interference, such as mold edges and conveyor belt texture.

[0120] 2. Feature extraction: Extract the geometric features, texture features, and grayscale features of defects from the preprocessed Region of Interest (ROI) image.

[0121] Geometric feature extraction: The Canny edge contour detection algorithm is used, with a low threshold of 50.0 and a high threshold of 150.0 to extract the edge contour of the defect; the contour curve is simplified by the contour approximation algorithm (Douglas-Peucker algorithm) to reduce redundant points.

[0122] Calculate the geometric parameters of the defect, including area, perimeter, roundness, and aspect ratio.

[0123] For bubble defects, focus on extracting areas ≥0.01mm. 2 For defects identified as valid defects, roundness (≥0.7 is considered a round bubble); for scratch defects, focus on extracting length (≥0.5mm) and aspect ratio (≥5.0); for missing material defects, focus on extracting the area of ​​the missing region (≥1mm²). 2 ).

[0124] Gray-scale feature extraction: Calculate the mean gray-scale value, variance gray-scale value, and extreme gray-scale value of the defect area. For example, due to the difference in internal light transmittance, the mean gray-scale value of the bubble area is 20 to 50 gray-scale levels lower than that of the normal area; the variance gray-scale value of the color difference defect area is more than 30 gray-scale levels higher than that of the normal area.

[0125] Texture feature extraction: The Gray-Level Co-occurrence Matrix (GLCM) algorithm is used to calculate the texture parameters of the defect region: contrast, correlation, and energy (reflecting the uniformity of the texture).

[0126] Normal vinyl toys have a uniform surface texture, an energy value ≥ 0.8, and a contrast ratio ≤ 50.0; while defective areas such as scratches and surface whitening have an energy value ≤ 0.5 and a contrast ratio ≥ 100.0. This characteristic can effectively distinguish texture defects.

[0127] 3. Defect detection and classification: Based on the extracted feature parameters, the trained AI model is used to automatically identify the defect type and determine its level.

[0128] 3.1 Feature Selection and Dimensionality Reduction: Principal Component Analysis (PCA) algorithm is used to reduce the dimensionality of the extracted geometric features, grayscale features, and texture features (a total of twelve features), retaining the first six principal components to reduce the computational load of the model.

[0129] 3.2 Defect Classification Model Inference: Call the pre-trained CNN convolutional neural network model (network structure: input layer → three convolutional layers → two pooling layers → two fully connected layers → output layer), and input the dimensionality-reduced feature vectors into the model.

[0130] The model outputs the probability distribution of twelve common defects (including bubbles, scratches, missing material, deformation, color difference, surface whitening, cracks, impurities, flash, sticking, dimensional deviation, and no defects). The category corresponding to the maximum probability is taken as the defect type (a confidence level ≥ 0.95 is considered a valid classification).

[0131] 3.3 Defect Level Determination: Based on the key parameters of the defect (area, length, grayscale difference, etc.) and in conjunction with industry standards, the level threshold is set to classify the defect into three levels.

[0132] Minor defects: bubble diameter ≤ 0.3mm, scratch length ≤ 1.0mm, color difference and grayscale difference ≤ 30.0, which do not affect the use and appearance of the product.

[0133] Moderate defects: bubble diameter 0.3-1.0mm, scratch length 1.0-3.0mm, missing material area 1-5mm. 2 It affects the appearance but not the structural strength.

[0134] Critical defects: bubble diameter > 1.0 mm, scratch length > 3.0 mm, missing material area > 5.0 mm², crack length > 2.0 mm, affecting product quality and safety in use.

[0135] 4. Abnormal situation judgment: By combining the detection results of single frame images, the time sequence analysis of multi-frame images, and the parameter correlation verification, false detections are eliminated, and abnormal situations in the production process are accurately judged.

[0136] 4.1 Single-frame image anomaly determination: If the number of moderate defects is ≥3.0 or the number of severe defects is ≥1.0, it is directly determined as a single-frame image anomaly. If the number of minor defects is ≥5.0 and the defects are concentrated (such as multiple bubbles appearing in the same area), it is determined as a potential anomaly, triggering subsequent time series analysis.

[0137] 4.2 Multi-frame image temporal analysis: Statistical analysis of the detection results of ten consecutive frames. If the frequency of abnormal defects is ≥8.0 frames, it is judged as a continuous abnormality.

[0138] If the abnormal defect only appears in 1.0-2.0 frames and the defect features are not clear, it is judged as a suspected false detection. The detection is then repeated by increasing the number of image acquisitions (acquiring three additional frames) to avoid misjudgment caused by momentary interference (such as water droplet obstruction).

[0139] 4.3 Parameter Correlation Verification: If the image detects bubble defects and the raw material viscosity data is >5000mPa・s and the molding temperature is <130℃, the anomaly judgment confidence level is increased to 0.99, confirming that the anomaly is caused by the mismatch between the raw material and process parameters.

[0140] If the image detects a material shortage defect, but the flow meter data of the feeding mechanism shows that the feeding amount is up to standard and the mold pressure sensor shows that the molding pressure is normal, it is judged as a suspected false detection, and the image preprocessing and detection process is repeated.

[0141] 5. Results Output and Feedback: Standardize the output of anomaly detection results and synchronize them to the comprehensive analysis module and alarm module to trigger adaptive adjustment or early warning actions.

[0142] Furthermore, the comprehensive analysis module performs a comprehensive analysis, including the following steps.

[0143] 1. Data Preprocessing: Integrate heterogeneous parameters from multiple sources during the production process, eliminate data noise and outliers, and provide standardized input for the model. Collect monitoring data from the image acquisition module, data acquisition module, image analysis module, and various sensors, and perform data cleaning and standardization processing on the data.

[0144] 2. Feature Engineering: Extract linear, nonlinear, temporal, and correlation features from the original parameters to enhance the model's ability to capture the relationship between process and quality.

[0145] 2.1 Basic Statistical Feature Extraction: Calculate statistical features for time series data of each type of parameter.

[0146] Numerical characteristics: mean, variance, maximum, minimum, extreme, median, mode, standard deviation.

[0147] 2.2 Time series feature extraction: The sliding window method (window size = 5.0 seconds) is used to extract time series trend features, including trend features and periodic features.

[0148] Trend characteristics: the rise and fall slope of parameters within the window (e.g., if the drop slope of cooling water temperature is >2℃ / s within five seconds, it is judged as excessively fast cooling), the rate of change of the mean within the window, and the frequency of extreme values ​​within the window.

[0149] Periodic characteristics: Periodic fluctuations of parameters are extracted by Fast Fourier Transform (FFT). For example, the periodic fluctuation amplitude of the flipping speed is >0.3 rad / s, which may lead to uneven molding.

[0150] 2.3 Parameter correlation feature extraction: Calculate the correlation features of key parameter pairs. There are a total of fifteen core parameter pairs, and two types of correlation features are extracted from each pair.

[0151] Correlation coefficient: The linear correlation of parameter pairs is calculated using the Pearson correlation coefficient. For example, when the correlation coefficient between raw material viscosity and feed rate is < -0.6, the risk of material shortage defects increases.

[0152] Cross-product and ratio characteristics: Construct nonlinear correlation characteristics between parameters, such as molding temperature × turning speed, primary water spray volume / primary cooling time, and tertiary cooling water / tertiary cooling time.

[0153] 2.4 Feature Selection and Dimensionality Reduction: The Recursive Feature Elimination (RFE) algorithm combined with random forest feature importance scoring is used to select core features.

[0154] 2.4.1: Calculate the importance score of each feature (value 0-1.0) using the random forest model, and retain features with a score ≥0.02 (remove irrelevant features, such as some statistical features).

[0155] 2.4.2: Redundant features are iteratively removed using the RFE algorithm, retaining a subset of features. Principal Component Analysis (PCA) is used to reduce the dimensionality of the selected features, retaining the top twenty principal components (cumulative variance contribution rate ≥ 90%), thus reducing the computational complexity of the model.

[0156] 3. Comprehensive evaluation model construction: Construct a comprehensive model integrating process evaluation, quality prediction and risk early warning, and adopt a multi-model fusion strategy to improve generalization ability.

[0157] 3.1 Model Construction: Gradient Boosting Tree (XGBoost) is used as the main model, supplemented by Support Vector Machine (SVM) and Medium LP (MLP) neural networks as auxiliary models. The prediction results are fused using a weighted voting method. The model division of labor is as follows: the XGBoost main model outputs the predicted product pass rate and the probability distribution of defect types; the SVM auxiliary model focuses on binary classification prediction of severe defects, compensating for the main model's insufficient detection of severe defects in small samples; the MLP neural network takes time-series features as input and predicts the stability score of process parameters.

[0158] 3.2. Model Input and Output Definitions: Input: 20-dimensional core feature vector after dimensionality reduction; Output: Comprehensive process evaluation score (0-100 points): ≥85 points is excellent, 70-84 points is good, 60-69 points is qualified, <60 points is unqualified.

[0159] Output the predicted product pass rate and the types and probabilities of potential defects. Based on the assessment score and defect probability, it is divided into three levels: low risk, medium risk, and high risk.

[0160] 4. Model Training and Optimization: Improve the model's prediction accuracy and stability through large-scale sample training and hyperparameter optimization.

[0161] 4.1 Training Dataset Construction: Collect at least one thousand batches of production data (covering different raw material batches, equipment status, and environmental conditions), and divide the data into training, validation, and test sets. Label the data, assigning each batch of data the actual product pass rate and defect type.

[0162] 4.2 Hyperparameter optimization: The Bayesian optimization algorithm was used to iteratively tune the hyperparameters of each model, with fifty iterations.

[0163] 4.3 Model validation iteration.

[0164] The validation metrics include...

[0165] Regression task (pass rate prediction): Mean absolute error (MAE) ≤ 2%, coefficient of determination (R²) 2 ≥0.92.

[0166] Classification task (defect type identification): accuracy ≥ 95%, recall ≥ 93% (for serious defects).

[0167] Overall evaluation score: Correlation coefficient with actual process score ≥ 0.9.

[0168] Model iteration: If the validation metrics are not met, supplement with one hundred batches of targeted data and retrain the model until the metric requirements are met.

[0169] 5. Comprehensive evaluation of the production process: Based on real-time collected parameter data, the trained model outputs a comprehensive evaluation result to quantify the rationality of the process.

[0170] 5.1 Real-time data input and feature calculation: The model receives preprocessed data of ten core parameters in real time, automatically calculates basic statistical features, time series features and correlation features, and generates a twenty-dimensional feature vector after dimensionality reduction by PCA.

[0171] 5.2 Multi-model fusion evaluation: The XGBoost main model outputs the process evaluation score, the predicted yield rate, and the probability of the top 3 defects. The SVM auxiliary model outputs the prediction results of severe defects; the MLP model outputs the process stability score.

[0172] The comprehensive evaluation model is as follows: S final =S base ×K defect ×K trend .

[0173] S base =1-SQT{[∑ i=1 (w i (Z i -Z i,opt ) 2 )] / ∑ i=1 (w i )}.

[0174] K defect =1-a[β1|rv-F|+β2(Q1 / t1)+β3(RT1 / 100)+β4(T4 / t3)+β5(T3 / t2)].

[0175] rv-F={∑[(Z v -Z v - (Z) F -Z F - )]} / {SQT[∑(Z v -Z v - ) 2 (Z F -Z F - ) 2 ]}.

[0176] K trend =1-γ×SQT{[∑ i=1 (w i |ki |)] / [∑ i=1 (w i )]}.

[0177] In the formula, S base This is the basic process adaptability score, reflecting the degree of matching between the current process parameters and the optimal process library. It is the core basic score for comprehensive evaluation. i Z is the weight coefficient of the i-th parameter, obtained by training with the random forest feature importance algorithm. i Z is the standardized value of the i-th parameter; i,opt It is the optimal standardized value of the i-th parameter; K defect is the defect risk correction coefficient, which, combined with the correlation characteristics between parameters (such as the correlation between viscosity and feed rate), corrects the base score to reflect the risk of defect occurrence. 'a' is the risk correction weight, controlling the influence of defect correlation characteristics on the correction coefficient, and is obtained through LSTM model training and optimization. β1, β2, β3, β4, and β5 are the correlation coefficients of the β5 parameter, corresponding to the weights of the correlation characteristics of the five core parameters, representing the degree of influence of different correlation relationships on defect risk. rv-F is the Pearson correlation coefficient between raw material viscosity and feed rate, reflecting the degree of linear correlation between raw material viscosity (V) and feed rate (F). The stronger the negative correlation, the higher the risk of material shortage defects. Q1 is the real-time water spray flow rate of the primary cooling box nozzle; t1 is the residence time of the product in the primary cooling box; T1 is the real-time average temperature in the constant temperature forming box; R is the real-time rotation speed of the flipping mechanism; T4 is the real-time water temperature in the tertiary cooling box; T3 is the residence time of the product in the tertiary cooling box; K trend γ is the time-series trend correction coefficient; γ is the strength of the influence of the time-series trend of the control parameter on the correction coefficient, which is obtained from historical data statistics; k i S is the temporal slope of the i-th parameter; final It is the final comprehensive evaluation score, a quantitative score that integrates basic adaptability, defect risk, and process stability, directly reflecting the overall rationality of the production process; SQT is the square root symbol; Z v It is the standardized value of the raw material viscosity; Z v - Z is the sample mean of the standardized values ​​of the raw material viscosity. F It is the standardized value of the raw material feed rate; Z F - This is the sample mean of the standardized values ​​of the raw material feed rate. T3 is the real-time water spray temperature of the nozzles in the secondary cooling chamber; t2 is the residence time of the product in the secondary cooling chamber.

[0178] 5.3 Visual output of evaluation results.

[0179] 6. Potential Risk Prediction: Based on the assessment results and parameter trends, predict the potential risks for the next one to five batches, achieving early warning. Risk prediction logic.

[0180] Short-term risk prediction: One or two batches of predictions are made based on the current time-series trend of parameters. The model is used to predict the evaluation score and defect probability of the next batch. If the predicted score is <70 or the probability of serious defects is ≥10%, it is judged as short-term high risk.

[0181] Long-term risk prediction: Three to five batches of predictions are conducted, combining historical data and using an LSTM time-series prediction model to predict parameter change trends. If the predicted process evaluation score continues to decline or the cumulative probability of a certain type of defect increases by ≥20%, it is identified as a long-term potential risk. Risk classification and early warning triggering.

[0182] Low risk: Comprehensive assessment score ≥80 points, defect probability ≤5%, stable trend, green indicator light, no audible or visual alarm.

[0183] Medium risk: 70 ≤ score < 80, or defect probability 5%-10%, trend fluctuation, yellow indicator light and intermittent audible and visual alarm.

[0184] High risk: Score < 70 points, or probability of serious defect ≥ 10%, with a worsening trend indicated by a red indicator light, continuous audible and visual alarms, and mobile app notifications.

[0185] The early warning information includes: risk level, predicted defect type, risk cause, and recommended measures.

[0186] The system automatically records the time of risk warning, triggering parameters, handling measures, and handling results, and links them to the traceability code of the corresponding production batch. If the process parameters are adjusted in place after the warning, the model will reassess in real time, and the alarm will be automatically lifted once the risk level drops to low risk.

[0187] This invention provides a method for producing vinyl toys, comprising the following steps.

[0188] S1. Pour the enamel material into the raw material tank 2 and tighten the tank lid 21. Activate the heating plate on the inner wall of the raw material tank 2, and in conjunction with the temperature sensor, heat the raw material to the process set temperature. Activate the stirring mechanism 3 to achieve uniform mixing of the raw material.

[0189] S2. Mold Installation and Preheating: Fix the multi-cavity mold 6 onto the inner rotating ring 53 of the flipping mechanism 5. Align the feed port 63 of the fixed template 62 with the direction of the feeding mechanism 8. Ensure smooth venting through the venting grooves on the inner wall of the mold cavity 64. Start the annular heating pipe and hot air circulation system of the constant temperature molding chamber 4 to preheat the mold to the molding temperature.

[0190] S3, Raw Material Injection: The multi-stage electric actuator 82 of the feeding mechanism 8 pushes the feeding nozzle 83 to open the heat insulation baffle 42 of the constant temperature molding box 4 and inserts it into the inlet 63 of the fixed template 62. The emulsification pump 81 is started, and the uniform raw material in the raw material tank 2 is injected into the mold cavity 64 through the feeding nozzle 83. The one-way valve in the inlet 63 prevents the raw material from flowing back. The flow meter monitors the feeding amount in real time. After the set value is reached, the solenoid valve closes.

[0191] S4. Flipping and Molding: After feeding is completed, the feeding nozzle 83 is withdrawn, the heat insulation baffle 42 is reset under the action of the reset spring, the constant temperature molding box 4 maintains a constant temperature, the flipping mechanism 5 assists in molding, the flipping mechanism 5 drives the mold to rotate horizontally and vertically synchronously, ensuring that the slush material is evenly distributed in the cavity and avoiding air bubbles and uneven molding.

[0192] S5. Mold Opening and Part Removal: After molding, the flipping mechanism 5 rotates the mold to a horizontal part removal position. The feeding mechanism 8 connects the nozzle to the air inlet. The high-pressure air pump supplies air to the multi-stage telescopic cylinder 551 of the mold opening mechanism 55 through a rotary joint, pushing the moving template 61 to open. The motor B91 of the starting sealing door assembly 9 drives the sealing door 93 to rise, opening the rectangular opening 43. The pick-and-place mechanism 7 adjusts its position through the multi-stage electric telescopic rods A71 and B72. The pneumatic suction cup 74 (or adaptive multi-suction cup) adsorbs the molded product, and the visual positioning module corrects the position. Then, the mold opening mechanism 55 drives the mold to close, the pick-and-place mechanism 7 resets, the sealing door closes, and the flipping mechanism 5 returns to the feeding position, waiting for the next batch of production.

[0193] S6. Gradient cooling: The pick-and-place mechanism 7 places the product on the conveyor belt assembly 13, and the conveyor belt sequentially sends the product into the primary cooling box 10, the secondary cooling box 11, and the tertiary cooling box 12 to complete the gradient cooling.

[0194] S7, the monitoring agency's image acquisition module acquires high-definition images of the vinyl toy production process. The data acquisition module acquires temperature and humidity data.

[0195] S8, the image analysis module analyzes the acquired images and promptly detects anomalies.

[0196] S9. The comprehensive analysis module integrates the monitoring results from the image acquisition module, data acquisition module, and image analysis module, combines them with historical data, conducts a comprehensive assessment, and predicts potential risks.

[0197] S10. When an abnormal situation or potential risk is detected, the alarm module issues an alarm.

[0198] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for producing vinyl toys, characterized in that, Includes the following steps: S1. Inject slush material into the raw material tank, start the heating plate on the inner wall of the raw material tank to heat the raw material, and start the stirring mechanism to mix the raw material evenly. S2. Fix the multi-cavity mold on the inner rotating ring of the flipping mechanism, start the annular heating pipe and hot air circulation system of the constant temperature molding box, and preheat the mold to the molding temperature. S3. The feeding mechanism injects the raw material from the raw material tank into the mold cavity through the feeding nozzle. S4. After feeding is completed, the feeding nozzle retracts, and the flipping mechanism drives the mold to rotate horizontally and vertically synchronously to ensure that the slush material is evenly distributed in the cavity. S5. After molding is completed, the flipping mechanism drives the mold to rotate to the horizontal part-taking position, the feeding mechanism drives the nozzle to connect with the air inlet, the high-pressure air pump supplies air to the multi-stage telescopic cylinder of the mold opening mechanism, and pushes the moving template to open; the sealing door assembly makes the sealing door rise, and the picking and placing mechanism adsorbs the molded product. S6. The pick-and-place mechanism places the product on the conveyor belt assembly, and the conveyor belt sequentially sends the product into the primary cooling box, the secondary cooling box, and the tertiary cooling box to complete the gradient cooling. S7: The monitoring agency's image acquisition module acquires high-definition images; the data acquisition module acquires temperature and humidity data. S8, the image analysis module analyzes the image and detects anomalies; S9, the comprehensive analysis module integrates multi-source data, combines it with historical data, conducts a comprehensive assessment, and predicts potential risks; S10. When an abnormal situation or potential risk is detected, the alarm module issues an alarm.

2. The method for producing vinyl toys according to claim 1, characterized in that: Step S8 includes the following steps: S81, Image Input and Preprocessing; S82. Feature Extraction: Extract the geometric features, texture features, and grayscale features of defects from the preprocessed Region of Interest (ROI) image. S83. Defect Detection and Classification: Based on the extracted feature parameters, the trained AI model is used to automatically identify the defect type and determine its level. S84. Abnormal Situation Judgment: By combining the detection results of a single frame image, the temporal analysis of multiple frames images, and the parameter correlation verification, false detections are eliminated, and abnormal situations in the production process are accurately determined. S85. Results Output and Feedback: Standardize the output of anomaly detection results.

3. The method for producing vinyl toys according to claim 1, characterized in that: Step S9 includes the following steps: S91: Acquire monitoring data from the image acquisition module, data acquisition module, image analysis module, and various sensors; perform data cleaning and standardization processing on the data. S92. Feature Engineering: Extracting linear, nonlinear, temporal, and correlation features from the original parameters to enhance the model's ability to capture the relationship between process and quality. S93. Construction of a comprehensive evaluation model: Construct a comprehensive model that integrates process evaluation, quality prediction, and risk early warning, and adopt a multi-model fusion strategy to improve generalization ability; S94. Model Training and Optimization: Improve the model's prediction accuracy and stability through large-scale sample training and hyperparameter optimization; S95. Comprehensive evaluation of the production process: Based on real-time collected parameter data, a trained model is used to output a comprehensive evaluation result to quantify the rationality of the process. S95.1 Real-time data input and feature calculation: The model receives preprocessed data of ten core parameters in real time, automatically calculates basic statistical features, time series features and correlation features, and generates a twenty-dimensional feature vector after dimensionality reduction by PCA. S95.2 Multi-model fusion evaluation: The XGBoost main model outputs the process evaluation score, the predicted yield rate, and the probability of the top 3 defects; the SVM auxiliary model outputs the prediction results of severe defects; and the MLP model outputs the process stability score. The comprehensive evaluation model is: S final =S base ×K defect ×K trend ; S base =1-SQT{[∑ i=1 (In i (WITH i -WITH i,opt ) 2 )] / ∑ i=1 (In i )}; K defect =1-a[β1|rv-F|+β2(Q1 / t1)+β3(RT1 / 100)+β4(T4 / t3)+β5(T3 / t2)]; rv-F={∑[(Z v -WITH v - )(WITH F -WITH F - )]} / {SQT[∑(Z v -WITH v - ) 2 (WITH F -WITH F - ) 2 ]}; K trend =1-γ×SQT{[∑ i=1 (w i |k i |)] / [∑ i=1 (w i In the formula, S base It is the basic process compatibility score; w i Z is the weight coefficient of the i-th parameter; i Z is the standardized value of the i-th parameter; i,opt It is the optimal standardized value of the i-th parameter; K defect α is the defect risk correction coefficient; α is the risk correction weight, obtained by LSTM model training and optimization; β1, β2, β3, β4 and β5 are the correlation coefficients of the β5 parameter, representing the degree of influence of different correlations on defect risk; rv-F is the Pearson correlation coefficient between raw material viscosity and feed rate; Q1 is the real-time water spray flow rate of the primary cooling box nozzle; t1 is the residence time of the product in the primary cooling box; T1 is the real-time average temperature in the constant temperature forming box; R is the real-time rotation speed of the flipping mechanism; T4 is the real-time water temperature in the tertiary cooling box; T3 is the residence time of the product in the tertiary cooling box; K trend γ is the time-series trend correction coefficient; γ is the strength of the influence of the time-series trend of the control parameter on the correction coefficient; k i S is the temporal slope of the i-th parameter; final It is the final comprehensive evaluation score; SQT is the square root symbol; Z v It is the standardized value of the raw material viscosity; Z v - Z is the sample mean of the standardized values ​​of the raw material viscosity; F It is the standardized value of the raw material feed rate; Z F - T3 is the sample mean of the standardized values ​​of raw material feed rate; T2 is the real-time water spray temperature of the nozzle in the secondary cooling box; t2 is the residence time of the product in the secondary cooling box. S95.3 Visual output of evaluation results; S96. Potential Risk Prediction: Based on the assessment results and parameter trends, predict the potential risks for the next one to five batches.

4. The method for producing vinyl toys according to claim 3, characterized in that: Step S 92 includes the following steps: S92.1 Basic Statistical Feature Extraction: Calculate statistical features for time series data of each type of parameter; S92.2, Time Series Feature Extraction: The sliding window method is used to extract time series trend features, including trend features and periodic features; S92.3 Parameter Correlation Feature Extraction: Calculate the correlation features of key parameter pairs; S92.4 Feature Selection and Dimensionality Reduction: A recursive feature elimination algorithm combined with random forest feature importance scoring is used to select core features; S92.4.1: Calculate the importance score of each feature using a random forest model; S92.4.2: Redundant features are iteratively removed using the RFE algorithm, a subset of features is retained, and principal component analysis is used to reduce the dimensionality of the selected features.

5. The method for producing vinyl toys according to claim 1, characterized in that: The stirring mechanism includes a motor A, a rotating shaft, a scraper, a ring, an outer stirring blade, and an inner stirring blade; A detachable lid is fixedly mounted on the raw material tank; a motor A is fixedly mounted on the top of the lid, and a rotating shaft is fixedly mounted on the output end of the motor A; a scraper is fixedly mounted on the rotating shaft; the scraper is in contact with the inner wall of the raw material tank; a dual-shaft motor is fixedly mounted on the rotating shaft, and a connecting rod is fixedly mounted on the output end of the dual-shaft motor; multiple inner stirring blades are mounted on the connecting rod; a ring is fixedly mounted on the outside of the connecting rod, and several outer stirring blades are evenly distributed on the ring.

6. The method for producing vinyl toys according to claim 1, characterized in that: The flipping mechanism includes an outer rotating ring, an outer shaft, an inner rotating ring, gear A, and a mold opening mechanism; A speed-regulating motor is fixedly installed under the base, and outer shafts are fixedly installed at the upper and lower ends of the outer rotating ring; the outer shafts are coaxially and fixedly connected to the output end of the speed-regulating motor. Two gear shafts are rotatably mounted on the outer rotating ring; an inner rotating ring is detachably fixed between the two gear shafts; a multi-cavity mold is detachably fixed on the inner rotating ring; a mold opening mechanism is fixed on the inner rotating ring; the multi-cavity mold includes a moving mold plate and a fixed mold plate, the fixed mold plate is detachably fixed on the inner rotating ring, the moving mold plate is slidably mounted on the inner rotating ring, and the moving mold plate is detachably fixedly connected to the mold opening mechanism; a gear ring is fixedly mounted inside the base, and a gear A is coaxially fixedly mounted on the outer end of the gear shaft, gear A meshes with the gear ring for transmission; an exhaust groove is provided on the inner wall of the cavity; the mold opening mechanism includes a multi-stage telescopic cylinder and a fixed plate; two multi-stage telescopic cylinders are fixedly mounted on the inner rotating ring, and a fixed plate is fixedly mounted on the end movable rod of the multi-stage telescopic cylinder, and the fixed plate is detachably fixedly connected to the moving mold plate.

7. The method for producing vinyl toys according to claim 1, characterized in that: The feeding mechanism includes an emulsifying pump, a multi-stage electric actuator, and a feeding nozzle; Multiple emulsifying pumps are fixedly mounted on the base; a multi-stage electric actuator is fixedly mounted on the base, and multiple feeding nozzles are fixedly mounted on the final movable rod of the multi-stage electric actuator; the feeding nozzles are connected to the output end of the corresponding emulsifying pump through pipelines; the input end of the emulsifying pump extends into the raw material tank; the feeding nozzles are movably inserted into the inlet of the multi-cavity mold, and an air inlet is provided on the inner rotating ring; a high-pressure air pump is fixedly mounted on the base; the output end of the high-pressure air pump is connected to a spout through a rotary joint and pipeline, and the spout is fixedly mounted on the final movable rod of the multi-stage electric actuator, and the spout is movably inserted into the air inlet, which is connected to the multi-stage telescopic cylinder through a pipeline.

8. The method for producing vinyl toys according to claim 1, characterized in that: The thermostatic molding chamber is equipped with heating elements; The heating element adopts a combination of ring heating tubes and hot air circulation. Eight sets of stainless steel heating tubes are evenly arranged around the inner wall of the constant temperature forming chamber. Together with the high-temperature axial flow fan at the top of the chamber, they form a forced hot air circulation, making the temperature inside the chamber uniform. Four temperature sensors are symmetrically set inside the forming chamber to provide real-time feedback on the temperature of different areas.

9. The method for producing vinyl toys according to claim 1, characterized in that: Monitoring agencies include: Data collection module: Collects data on vinyl toy production equipment, vinyl toy production processes, and design data; collects historical data; and annotates the data. Image acquisition module: includes a high-definition camera to capture high-definition images of the vinyl toy production process; Data acquisition module: includes temperature and humidity sensors, which collect temperature and humidity data; Image analysis module: Analyzes the acquired images to promptly detect anomalies; Comprehensive Analysis Module: Integrates multi-source data, combines it with historical data, conducts a comprehensive assessment, and predicts potential risks; Alarm module: includes an alarm that sounds when an abnormal situation or potential risk is detected; PLC control module: This is a programmable control module that is networked with data collection module, image acquisition module, image analysis module, comprehensive analysis module, alarm module, stirring mechanism, tilting mechanism, pick-and-place mechanism, feeding mechanism, sealing door assembly, and conveyor belt assembly.

10. A type of vinyl toy manufacturing equipment, comprising: The components include a base, a raw material tank, a mixing mechanism, a constant temperature molding chamber, a tilting mechanism, a multi-cavity mold, a pick-and-place mechanism, a feeding mechanism, a primary cooling chamber, a secondary cooling chamber, a tertiary cooling chamber, and a conveyor belt assembly; characterized in that: A constant temperature molding chamber is fixedly installed on the top of the base; a raw material tank is fixedly installed on the right side of the constant temperature molding chamber, and a stirring mechanism is installed on the raw material tank; a flipping mechanism is rotatably installed inside the constant temperature molding chamber via a bearing seat; a multi-cavity mold is detachably fixedly installed on the flipping mechanism; a feeding mechanism is fixedly installed on one side of the raw material tank, and the feeding mechanism is inserted and cooperated with the multi-cavity mold. The left side of the constant temperature forming chamber is provided with a primary cooling chamber, a secondary cooling chamber, and a tertiary cooling chamber. The primary cooling chamber is equipped with a loading and unloading mechanism. A conveyor belt assembly is provided between the primary, secondary, and tertiary cooling chambers. A high-temperature water tank, a medium-temperature water tank, and a low-temperature water tank are fixedly installed above the base. Water pumps are installed in the high-temperature, medium-temperature, and low-temperature water tanks. Several nozzles are fixedly installed on the inner walls of the primary and secondary cooling chambers. The nozzles on the primary and secondary cooling chambers are connected to the water pumps in the high-temperature and medium-temperature water tanks through pipelines.

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