Optical cable water-blocking filling line adaptive closed-loop control method

Abstract

The application discloses a water-blocking filling line adaptive closed-loop control method for an optical cable and relates to the technical field of optical cable process control. The method comprises the following steps: collecting quality flow-density-temperature, pressure and front information, calculating target quality flow, equivalent viscosity and generating a safety margin; synchronizing the metering pump speed with the traction speed according to the target quality flow, constructing a head front pressure target trajectory, and shaping the transient state of the micro-bypass and back pressure; when the safety margin is positive, linking the traction speed, vacuum sizing and pump speed micro-correction around the equivalent filling rate, outer diameter and fiber excess length; using two-phase indicators and equivalent volume modulus to trigger threshold functions to realize staged limiting and controlled shutdown, and generating evidence summary quantities according to the roll; and the method can inhibit under-filling and backflow, stabilize the outer diameter and fiber excess length, shorten the transition section, strengthen the traceability, and support cross-line replication and batch comparison landing.

Description

Technical Field

[0001] This invention relates to the field of optical cable process control technology, specifically to an adaptive closed-loop control method for optical cable water-blocking filling lines. Background Technology

[0002] In optical cable manufacturing, the water-blocking filling process for loose tubes or bundled tubes typically uses jelly-like or paste-like materials, continuously completed through units such as degassing tanks, circulating heating, metering pumps, filling heads, vacuum sizing, and traction. Existing production lines often incorporate dual-circulation stable glue supply, precision metering, and advanced detection methods, along with jelly-forming molds to improve local flow fields, while also meeting compliance tests for dripping, flow, and longitudinal water seepage. However, in real production line scenarios, frequent start-ups and shutdowns, shaft changes, order switching, and line speed adjustments are unavoidable. The glue material also exhibits thixotropic and non-Newtonian properties, making it extremely sensitive to temperature and shear. The piping and glue system contain volumetric elasticity and residual microbubbles, the transient pressure drop of filters and valves changes abruptly with line speed, local disturbances within the filling head are amplified, and there are response lags and coupling issues in the measurement and execution processes.

[0003] The combination of these factors makes it easy for the injected mass flow rate, the pressure before the filling head, the position of the filling front, and the fiber excess length to deviate asynchronously during the transient phase: during acceleration, the pressure surge and flow lag cause backflow and outer diameter drift; during deceleration, the sudden drop in back pressure causes underfill and voids. In micro-cable and high linear speed scenarios, the annular gap is narrower and the tolerance is smaller, and the fiber excess length is particularly sensitive to small disturbances, which manifest as amplified fluctuations and periodic jumps.

[0004] Current methods for adjusting injection volume using single-point signals are limited by univariate feedback and sensing delays, making it difficult to cover the multivariate transient coupling between injection, traction, sizing, and temperature. While equipment-level constant viscosity and pressure or flow field optimization can improve steady-state consistency, they still highlight the challenges of rapid imbalances and transient deviations under acceleration and deceleration trajectories. Offline criteria are difficult to map to process control in a timely manner, and operators often rely on experience windows for parameter adjustment, resulting in insufficient consistency, increased scrap and rework, increased equipment contamination and cleaning burden, and impacting delivery and reputation. If this continues long-term, it can easily expose potential problems such as material migration, dripping, and void connectivity under subsequent thermal cycling, low-temperature bending, and long-term vertical placement conditions, leading to decreased yield and delayed rework.

[0005] Therefore, the current problem is that under transient conditions such as start-up, shutdown, and changes in linear speed, the combined effects of factors such as material rheological properties, the bulk elasticity of pipelines and adhesives, residual air bubbles, and measurement and execution lags cause systematic asynchrony and mismatch between the injected mass flow rate, the pressure before the filling head, the filling front edge, and traction. This leads to underfilling, backflow, outer diameter fluctuations, and sudden changes in fiber optic excess length, and makes it impossible to effectively constrain compliance requirements such as dripping and longitudinal water seepage during the production process. Summary of the Invention

[0006] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides an adaptive closed-loop control method for water-blocking filling lines in optical cables. This method synchronizes the metering pump speed with the traction speed based on the target mass flow rate, constructs a target pressure trajectory before the head, and shapes the transient state using micro-bypass and back pressure stabilization. With a positive safety margin, it links the traction speed, vacuum sizing, and pump speed with minor corrections based on the equivalent fill rate, outer diameter, and fiber excess length. By utilizing two-phase indication and equivalent bulk modulus to trigger threshold functions, it achieves graded limiting and controlled shutdown, and generates evidence summary quantities per roll. This method can suppress underfilling and backflow, stabilize the outer diameter and fiber excess length, shorten the transition section, and enhance traceability, thus solving the technical problems described in the background art.

[0007] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: An adaptive closed-loop control method for water-blocking filling lines in optical cables includes: collecting mass flow rate-density-temperature, pump outlet and filling head pressure, temperature, leading edge and equivalent filling rate, outer diameter, traction speed and fiber excess length; estimating equivalent viscosity based on this, calculating the target mass flow rate and generating a safety margin; Based on the target mass flow rate, the metering pump speed and traction speed are synchronized to construct the target pressure trajectory in front of the head; a micro-bypass and back pressure stabilization are set between the metering pump and the filling head, and the pump speed slope and the maximum opening of the bypass are limited according to the safety margin. With a positive safety margin, the traction speed, vacuum sizing and pump speed are adjusted in conjunction with the deviation of equivalent fill rate, outer diameter and fiber length based on the equivalent fill rate, outer diameter and fiber length deviation, and are checked against the target trajectory of the front pressure. Two-phase indicators are constructed based on density changes and driving energy, and the equivalent bulk modulus is identified by small pressure-flow rate tests, triggering graded limiting and controlled shutdown; temperature, pressure, mass flow rate, safety margin and key actions are summarized by roll to generate traceability records.

[0008] Furthermore, the mass flow rate, density, temperature, pump outlet and filling head pressure, temperature, front edge and equivalent filling rate, outer diameter, traction speed and fiber excess length are aligned on a unified time base, and the annular gap geometry and density benchmark are checked when changing the mold or specification, and the equivalent viscosity and target mass flow rate are generated by binding according to the work order number.

[0009] Furthermore, when generating the safety margin, the exposure amount exceeding the temperature threshold is statistically calculated according to the sliding time window. The equivalent viscosity, filling rate, annular geometry, and attitude angle are combined to form a drip risk index. The remaining amount corresponding to this index is then used to form the safety margin, which is published along with the timestamp to subsequent steps.

[0010] Furthermore, the metering pump speed is driven by the target mass flow rate and synchronized with the traction speed. The slope of the pump speed change is limited according to the safety margin. The target trajectory of the front pressure is formed by superimposing the base back pressure, the target mass flow rate and its rate of change. The trajectory provides a reference for bypass and back pressure control under a unified time base.

[0011] Furthermore, a micro-bypass is set between the metering pump and the filling head and connected in series with a back pressure regulator. The micro-bypass uses a high-speed proportional valve to divert or recover the flow, and the back pressure regulator maintains the basic back pressure. When the target trajectory of the pressure in front of the head deviates from the actual measurement, the maximum opening of the bypass and the pump speed step are adjusted according to the safety margin, and the pump speed is kept in the same phase as the traction speed.

[0012] Furthermore, before entering the main channel, preheating, pre-circulation, and pre-compression are performed in sequence: the loop is raised to the target window according to the temperature setting, and the loop is circulated in the micro-bypass until the equivalent viscosity is stable. Then, the basic back pressure is established by back pressure stabilization. After completion, the main channel is opened and the micro-bypass is kept at the reference opening for standby.

[0013] Furthermore, using the equivalent fill rate, outer diameter, and fiber excess length as a unified target, the linkage between traction speed, vacuum sizing, and pump speed micro-correction is obtained based on the sensitivity matrix and the generalized inverse first solution; traction speed and vacuum sizing are executed first, followed by pump speed micro-correction, and the results are checked against the target trajectory of the front pressure.

[0014] Furthermore, the equivalent fill rate is weighted and fused by the health status of measurements from capacitive loop, thermal, or micro-pressure differential probes, and the fiber excess length is composed of traction differential speed, traction tension, and cooling process as proxy quantities. The three are unified in the time base calculation deviation and used as input for solving the linkage quantity.

[0015] Furthermore, the two-phase indication is composed of the time accumulation of density change rate and driving energy ratio. The equivalent bulk modulus is identified by small pressure and volumetric flow rate during the micro-bypass circulation stage. When the two trigger the threshold, the base back pressure is increased in sequence, the maximum bypass opening is tightened, and the pump speed step and phase are adjusted.

[0016] Furthermore, a threshold function is formed by combining safety margin, two-phase indication quantity and equivalent bulk modulus. The dwell time and transfer conditions are set in the order of operation, warning, degradation and controlled shutdown. An evidence summary quantity is generated at the end of each volume. The summary quantity is archived in association with the volume number, work order number and timestamp.

[0017] (III) Beneficial Effects This invention provides an adaptive closed-loop control method for water-blocking filler lines in optical cables, which has the following beneficial effects: Transform standard criteria into calculable safety margins and generate target mass flow rate and equivalent viscosity under a unified time base, so that subsequent steps can be connected with data of the same caliber, reduce trial and adjustment uncertainty, and ensure that risk boundaries are controlled. The target mass flow rate drives the metering pump speed and traction speed synchronously, and the head pressure target trajectory is combined with micro-bypass and back pressure stabilization to perform transient pressure shaping. The pump speed slope and the maximum opening of the bypass are limited according to the safety margin. During the speed change and start-up phases, underfilling and backflow are suppressed, and the equivalent filling rate and outer diameter are stabilized. Preheating, pre-circulation, and pre-compression are set to pre-push temperature, pressure, and equivalent viscosity into the target window, and establish basic back pressure before entering the main channel to ensure that the material state in the first section is consistent, shorten the transition section, and reduce fluctuations and human intervention after mold change. Under the constraint of positive safety margin, the equivalent filling rate, outer diameter and fiber excess length of the unified target organization are determined by the linkage solution of the sensitivity matrix and executed in the order of priority of traction speed and vacuum sizing, and bottoming out of slight correction of pump speed. This ensures that the three quality constraints are coordinated in the same decision and avoids mutual interference of single-point adjustment. Two-phase indicators are constructed using density changes and driving energy, and the equivalent bulk modulus is identified during the bypass cycle stage. The sequence of operation, warning, degradation and controlled shutdown is organized by combining threshold functions, so that gas-containing and compliance disturbances are absorbed at the front end of the loop, and the abnormal handling is bounded and resettable. The evidence summary is generated by volume, and the critical path is associated with temperature, head pressure, target mass flow rate, bypass opening and safety margin to form a searchable traceability record. This ensures that the production line expresses compliance criteria and process trajectory in a consistent manner, facilitating cross-line replication and batch comparison. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the adaptive closed-loop control method for the water-blocking filling line of the optical cable according to the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Please see Figure 1 This invention provides an adaptive closed-loop control method for water-blocking filler wires in optical cables, comprising: Step 1: Transform the key quantities that determine quality and compliance into measurable, estimable, and constrainable online metrics, and generate three primitive quantities that can be directly invoked in the subsequent three steps: target quality flow. Equivalent viscosity Safety margin .

[0021] When the production line switches specifications and changes speed, the annular gap geometry, linear velocity, and compound state jointly determine whether the filling can proceed stably. If a stable target mass flow rate and equivalent viscosity are lacking, any subsequent actions will become passive compensation; therefore, it is necessary to first integrate geometry, linear velocity, and material properties into a feasible calculation link, and keep the symbols and parameters consistent throughout the entire line.

[0022] The inner diameter of the sleeve in the work card is mapped to the equivalent fiber bundle diameter as the annular gap cross-sectional area. The linear velocity time trajectory is combined with the target filling rate and the rubber density to generate the target mass flow rate. The equivalent viscosity is then estimated using the pressure difference between the metering pump outlet and the filling head, the volumetric flow rate, the temperature, and the density. The temperature and shear parameters are then used for physical correction, providing a direct-drive feedforward for pump speed and temperature setting for the second step. On-site, the inner diameter of the sleeve and the equivalent fiber bundle diameter are first confirmed according to the work card, and then checked once after mold change as per team practice; the linear velocity time trajectory is issued by the wired control host computer.

[0023] Therefore, by feeding these three factors, along with the target filler ratio and compound density, into a unified expression, the target mass flow rate is obtained. ; and the linear velocity time trajectory is smoothed into an executable feedforward curve using cubic spline interpolation to ensure subsequent in-phase following, wherein: Where: target mass flow rate Mass injected into the annulus per unit time; unit conversion factor Unify the units of geometry and velocity to constants required for mass flow rate, eliminating dimensional differences, and assign a fixed value; rubber density. Density measurement provided by a mass flow-density-temperature integrated instrument reflects the influence of batch and temperature on mass flow rate, and the value is positive; Annular gap cross-sectional area The effective flow area, calculated from the inner diameter of the sleeve and the equivalent fiber bundle diameter, maps geometry to flow capacity; to ensure... A consistent caliber is used to specify the cross-sectional area of ​​the annular gap. =The formula for calculating the area of ​​a torus is recorded and stored in the database after mold change to avoid deviations caused by different calculation methods.

[0024] linear velocity The linear velocity-time function provided by the traction system determines the distance traveled per unit time; target fill rate. The target geometric filling ratio of this structure is used to define the space ratio, with a value between 0 and 1. target quality flow As the sole reference for pump speed feedforward, cubic spline interpolation is used for Smooth time trajectory; annular gap cross-sectional area The diameter is calculated from the corresponding diameter on the work card and verified after mold change; unit conversion factor. Target mass flow rate is calibrated once during process line setup. The same time reference is used for generating the target trajectory of the head pressure in the second step to avoid phase difference.

[0025] Through target quality flow The unified generation ensures that the pump speed feedforward and traction speed remain in phase on the time axis, reducing the inconsistent speeds that cause the feedforward to fluctuate. This is due to the annular gap cross-sectional area. , and exist With multiplicative coupling, batch density and geometric changes are directly mapped to the feedforward, reducing the initial deviation caused by differences in work cards.

[0026] Pressure is simultaneously measured at the metering pump outlet and in front of the filling head, and the pressure difference is obtained by subtracting the two; the volumetric flow rate is taken from the instantaneous reading of the integrated instrument; the temperature and density entries are paired with it to form a time-synchronized quaternion.

[0027] To avoid relying solely on empirical temperature curves, an equivalent viscosity expression incorporating activation and shear terms is constructed, separating the effects of temperature and shear and allowing for individual term-by-term correction. Where: equivalent viscosity : A quantity characterizing the flow resistance of the rubber compound under the current pressure difference and volumetric flow rate, with a positive value; hydraulic constant The proportionality coefficient, calculated from the hydraulic resistance of the loop, converts the pressure difference and volumetric flow rate into the dimension of viscosity and is a fixed constant. Pressure difference : Metering pump outlet pressure minus filling head pressure, the value is non-negative; volumetric flow rate Integrated instrument readings, depicting flow rate, with non-negative values; temperature. : Temperature before filling head, adjusted during activation, and the value should be a positive number within the allowable range of the process; Reference temperature The reference temperature selected during line establishment is a fixed constant; activation energy. The temperature sensitivity parameter of the rubber compound flow determines the slope of the activation term, which is positive; gas constant. Physical constants, used to dimensionally standardize the activation terms, and are fixed constants; Shear coefficient : Shear correction scaling factor, used for incremental correction in high-shear regions, non-negative; shear exponent The power exponent of the shear correction determines the growth pattern of the effect of shear strength, and is non-negative; Shear rate : Characteristic quantities related to volumetric flow rate and annular geometry, are non-negative, where shear rate The calculation aperture adopts the engineering annular gap approximation, and is defined as follows: in, Let be the hydraulic radius, and take the value. , The inner radius of the casing, The equivalent radius of the fiber bundle; the scaling factor. The annular gap correction factor is calibrated through a single small disturbance test in the bypass circulation stable section and then solidified into the database (selectable). The initial value is Then make minor adjustments based on the same batch of materials.

[0028] Align the above quadruplets according to their timestamps; activation energy in the activation term. Obtained through single-shift calibration and verified during batch switching; shear coefficient in the shearing item. With shear index To avoid parameter drift, a set of fixed values ​​was taken at different linear speed settings; to prevent reading spikes, the volumetric flow rate was... With temperature Three-point median filtering is applied; the expression is solved using direct substitution, avoiding unnecessary iterations; the generated equivalent viscosity... The second step is used for the synchronous adjustment of temperature setting and pump speed gain.

[0029] Therefore, the separate corrections for temperature and shear allow batch variation and linear velocity changes to be handled separately, reducing the excessively wide window caused by a single temperature compensation. Equivalent viscosity With target quality flow The matching generation ensures that the feedforward and physical properties are of the same origin on the time axis, avoiding the phenomenon that the viscosity lags behind even when the speed increases.

[0030] Furthermore, the criteria for determining dripping versus flow have long remained in offline laboratory settings, with production lines lacking corresponding online quantities. This forces work teams to rely on experience to leave excessive safety margins, sacrificing convergence speed and material utilization efficiency.

[0031] Therefore, the offline criteria need to be decomposed into a combination of three online quantities: temperature exposure, geometric attitude, and rheological level, and a safety boundary that is updated over time needs to be generated for subsequent actions.

[0032] Therefore, by using the obtained equivalent viscosity The temperature exceedance during the sliding time is constructed in the temperature channel; the filling rate, annular geometry, and running attitude are combined into an attitude function, and the product of the three is used to form a dripping risk index. Then, with a safety margin Expressed as one minus the risk index ,when As the flow rate approaches zero, subsequent actions must tighten the range of temperature, flow rate, and linear velocity.

[0033] Using a fixed-length sliding time window along the temperature channel, perform time integration on the portion above the critical temperature; then compare the integration result with... The relative quantities and attitude functions are multiplied to form a risk expression; to avoid false alarms caused by temperature reading fluctuations, the sliding integral is calculated using a trapezoidal quadrature, the time window is consistent with the shift production schedule, and the readings are entered into the database according to a unified time base, wherein: Where: dripping risk index : Characterizes the risk level of dripping or flowing under current operating conditions; upper limit constraint trigger amount; equivalent viscosity : Same meaning as before; reference viscosity Based on the preset reference viscosity of the structure and materials, its function is to... Dimensionless, positive; sliding time : The length of the time window used for temperature exposure integration, which is positive; time variable Integral variables : Define the time interval on a unified time axis, and take non-negative values; Temperature function The time function of the temperature channel provides the thermal history input. It refers to a temperature measurement channel over time in a process, based on a unified time base. The changing temperature curve; Critical temperature : The threshold at which the material begins to exhibit flow risk, capturing the effective heat exposure; positive part operator Operator that truncates negative values ​​to zero; attitude function The target fill rate, annular gap cross-sectional area and running attitude angle are mapped together to a geometric-attitude influence factor, which allows spatial factors to be included in the risk expression and takes a positive value. attitude function Positive value mapping in exponential form: The coefficient is a non-negative tradeoff. As the benchmark for the work card; This refers to the operating attitude angle. The parameters can be obtained through the regression setpoint temperature channel of two sets of type-specific temperature detection zones. Cubic spline reconstruction is employed, and integration is performed using trapezoidal quadrature with a time window. Consistent with the type inspection caliber.

[0034] Target fill rate Annular gap cross-sectional area : Same meaning as before; attitude angle : Spatial angles during equipment installation and operation, characterizing the influence of gravity and attitude on flow, with values ​​ranging from 0 to Within the range; Among them, the temperature channel is reconstructed as a continuous curve using spline interpolation; the sliding integral is calculated using trapezoidal quadrature; the critical temperature... Compared with reference viscosity Set and store the attitude function once before the new material is launched. This can be obtained using a lookup table method, with the table entries generated during the process trial production stage; integration window. Maintaining the same time base as the type test temperature ensures consistency between risk expression and judgment criteria.

[0035] Temperature exposure, viscosity level, and geometric orientation are three quantities in The multiplicative coupling between the two means that any deviation will immediately be reflected as an increase in risk, avoiding misjudgments caused by looking only at temperature or flow rate. The calculations do not rely on hard-to-obtain hidden variables; they all come from the already connected channels, making them easy for work teams to execute.

[0036] The safety margin is generated by subtracting the risk index from one. When the safety margin As the point approaches zero, the linear velocity feedforward and the target trajectory of the head-forward pressure in the second step will automatically narrow their variation range accordingly, and the traction, vacuum sizing, and temperature setting in the third step will be delayed or mitigated accordingly. To ensure consistency across all layers, The message is published using both a timestamp and a work order number as identifiers in the message channel. Where: safety margin : Represents the remaining space from the risk threshold, serving as a higher-level constraint for subsequent actions; Risk Index The meaning is the same as before; Safety margin and , Write it together to the process data bus, using a unified clock for the timestamp; when there is a safety margin When the speed is below the set threshold, a limiting command is issued, including the upper limit of the pump speed change slope, the maximum opening of the bypass valve, and the upper limit of the linear velocity increase; if there is a safety margin... If multiple consecutive frames are negative, the controlled shutdown process in step four is triggered. The release format uses key-value pairs and maps to the production database fields for easy traceability.

[0037] safety margin The remaining metric of the compliance space is expressed as a single value, providing a clear convergence boundary for subsequent actions; safety margin. and , Same-origin releases eliminate the need for redundant decision-making logic in the second and third steps at the execution level, reducing instruction conflicts.

[0038] Step 2: Target quality flow rate As the sole feedforward reference, with equivalent viscosity As a basis for temperature and gain correction, with a safety margin To constrain the variation range, the pump speed and traction speed are synchronized, and the pressure trajectory in front of the filling head is used as the anchor point to complete the transient shaping, thereby turning the jittery process into a controllable continuous trajectory.

[0039] During startup and speed change, if the pump speed and traction speed are not synchronized, the advance speed of the filling front will fluctuate, leading to local underfilling or backflow.

[0040] The target quality flow rate has been given in the previous stage. With equivalent viscosity Therefore, it is necessary to couple the pump speed and traction speed on the same time base, and to allow the slope of the feedforward curve to have a safety margin. The constraints should be avoided to prevent drastic changes from pushing the pressure to the brink of risk.

[0041] First, use the target quality flow rate. The time trajectory constructs a slope-constrained update of the pump rate, causing the pump rate to move between walk distances. The direction of change is steadily advancing; then, based on the target quality flow rate... Its derivative generates the head pressure target This directly links pressure changes before the filling head to material throughput, providing a reference for subsequent bypass diversion and back pressure stabilization. Due to safety margins... As generated in the previous stage, the upper limit of the pump speed slope and the width of the pressure target envelope are both based on... The threshold can be tightened or loosened at any time, thus ensuring that the safety boundary is maintained for every step.

[0042] Read target quality traffic at the same timestamp With traction speed To prevent excessively large jumps in pump speed within a single step, an upper limit on the slope is introduced. (Based on safety margin) (Adjustment), using discrete bounded incremental updates to improve pump speed and The direction of change is consistent, the stride is limited, and the rhythm is consistent with In phase. Based on this, the pump speed update relationship is given: Among them, pump speed The speed of the metering pump, used to drive injection; pump speed. exist The values ​​at each sampling time point; time nodes , : A time series with strictly increasing values ​​at adjacent sampling times; target mass flow rate : The time series output from the previous stage; Upper limit of slope The maximum permissible rate of change of pump speed per unit time, determined by the safety margin. Control the upper limit, tightening it when there is high risk; among them, the upper limit of the slope. The mapping is: This is the upper limit of the maximum allowable slope for machinery. This is a safety margin trade-off constant. The derivative is calculated using forward difference and a first-order low-pass filter. First, reconstruct the structure using cubic splines, then take the derivative; Time step : The time difference between adjacent sampling times, with a positive value, used to calculate the allowable step size; Scale factor The coefficient for converting the mass flow rate difference into pump speed step size is positive; sign function. The output is , or The sign operator; used to determine the direction of increase or decrease; the minimum value operator. Choose the smaller of the two numbers; At each time node First calculate the target mass flow rate. The difference, and then based on the safety margin Dynamically set the upper limit of slope The upper limit is then substituted into the above formula to obtain the pump speed. To maintain traction speed To ensure that the pump speed stepping and traction speed updates are synchronized in time, the work team will reconstruct the traction speed curve using the same sampling time base.

[0043] Thus, the single-step change of pump speed is limited to a controllable range, avoiding pressure spikes caused by excessively fast feedforward; the pump speed and traction speed advance synchronously on the same time base, the advance speed of the filling front is more stable, and the probability of underfilling and backflow is reduced.

[0044] Pump speed synchronization alone is insufficient to flatten transient pressure; therefore, the target mass flow rate is used. The target head pressure is generated by taking its rate of change as input. During construction, the foundation back pressure is applied. Starting from this point, a traceable pressure target is formed using the mass flux term and the rate of change term, thus providing a clear reference for bypass diversion and back pressure stabilization: Where: Head pressure target : The expected pressure trajectory before filling the head, used as a reference for subsequent bypass and back pressure tracking; base back pressure The constant back pressure preset for a stable flow field is determined by the hardware performance and structure of the equipment; coupling coefficient : The linear mapping coefficient of mass flux to pressure target, calibrated during pipeline establishment; coefficient of variation : The rate of change of flux as a modulator of the pressure target, used to suppress overshoot and undershoot; target mass flow rate : Same meaning as before, takes a positive value; time derivative The rate of change calculated by forward difference on the same time base is used to express different needs for acceleration and deceleration; Reconstruct using cubic splines The continuous curve is then calculated using forward difference. To avoid burrs; when the safety margin is sufficient When the reduction is made, the work team shall simultaneously reduce the amount according to regulations. and The upper limit makes the head pressure target The envelope automatically narrows. Anterior pressure target. The next sub-step will involve measuring the pressure in front of the head. In contrast, it is used for bypass shunting and back pressure stabilization.

[0045] When in use, the pressure target is linked to the mass flux to avoid mismatch caused by adjusting the pump speed without considering the pressure; the rate of change term is introduced to reduce the surge and fall during acceleration and deceleration, leaving a time window for the subsequent actions of bypass and back pressure.

[0046] Even if the pump speed and traction speed are in phase, the energy stored in the viscoelastic material in the loop will still push the pressure in front of the head outwards. A path for rapid diversion and pressure release must be set up before the filling head, and the pressure peak and tail rebound should be absorbed in the bypass loop using the base back pressure as an anchor. At the same time, through preheating-pre-circulation-pre-compression, the equivalent viscosity and pressure are brought into the target window before the line is opened, avoiding the introduction of unstable sections into the finished product.

[0047] Firstly, based on the target of anterior head pressure. Compared with the measured pressure The difference is used to solve for the bypass valve opening. The bounded adjustment amount, and set with a safety margin. The relevant upper limit of the opening ensures priority diversion when risks increase; then, the equivalent viscosity is... The deviation is directly converted into temperature setting. Fine-tuning the amount and establishing a base back pressure during the bypass loop phase. This ensures that the material state and pressure state upon entering the main channel are both within the target window.

[0048] The main function of the bypass valve is to... and The difference is absorbed locally to prevent the main channel from experiencing excessively rapid pressure rises or falls. To this end, a bounded proportional update is introduced, and a limiting function is used to hard-limit the opening, ensuring it is within a safety margin. Collaboration: Where: Bypass valve opening degree Bypass valve at all times The opening percentage, ranging from 0 to 1; limiting function. :when Pick ,when Pick Otherwise take Used to implement hard limits; minimum opening The minimum effective opening above the mechanical zero position, with a value between 0 and 1; the maximum opening. Safety margin The upper limit of the linkage ranges from 0 to 1. It tightens as it decreases; Reference opening The steady-state small opening, serving as the starting point for adjustment, takes a value between 0 and 1; the proportional coefficient. The coefficient that maps the pressure difference to the valve opening increment is calibrated based on the circuit volume and valve characteristics; the target pressure at the beginning of the valve. Output from the previous step; Actual measurement of anterior head pressure. The pressure measured by the sensor in front of the filling head is positive; , as the benchmark upper limit ， As a relaxation factor, Indicator functions Take when the condition is met That is: when the target is higher than the measured value ( (Needs to release pressure) and When the flow decreases (risk increases), the maximum opening is automatically widened to divert traffic; when... Maintain the baseline upper limit to avoid excessive bypass leading to undervoltage.

[0049] At each sampling time, first read and With proportionality coefficient Calculate the opening increment, then apply the limiting function to the mechanically reachable range; when the safety margin... When decreasing, through the function Automatically reduce the maximum allowable opening, so that diversion capacity is released preferentially in high-risk areas; When in use, the upward pressure in front of the head is absorbed locally by the bypass, reducing disturbance to the main channel; during the descent phase, the bounded recovery of the bypass avoids undervoltage and backflow, maintaining the continuity of the leading edge advance.

[0050] Temperature settings need to be closely aligned with equivalent viscosity. To mitigate deviations and automatically pull the material back to the target window without manual intervention, a logarithmic mapping is used to convert the ratio of equivalent viscosity to reference viscosity into a temperature correction; simultaneously, a base back pressure is established during the bypass circulation phase. This allows the pressure field and the rheological field to reach a consensus before entering the main channel: Among them, temperature setting At any moment The target heating temperature is used to adjust the rheological level of the rubber compound; the reference temperature. The reference temperature during line construction serves as the starting point for correction; temperature mapping coefficient. A coefficient mapping viscosity ratio to temperature offset, given based on material activation characteristics; reference viscosity. : Target viscosity corresponding to the structure and formulation, used as a dimensionless benchmark; equivalent viscosity : The online estimate from the previous stage, with a positive value; During the preheating phase, follow the set temperature. Gradual temperature increase; during the pre-cycle phase, maintain a clear bypass to ensure equivalent viscosity. With temperature setting A consensus was reached; during the pre-compression phase, the base back pressure was adjusted using a back pressure regulator. Raise to the designated scale and maintain it for a short time to squeeze out the compressibility within the loop; after completing the three segments, the main channel opens, while the bypass remains at the reference opening. Standby; thus, temperature correction ensures that the equivalent viscosity remains stable within the target window, reducing flux fluctuations caused by rheological drift; establish basic back pressure before entering the main channel, so that the pressure and viscosity of the first section of material are already matched, reducing the scrap of the first section.

[0051] Step 3: Within a safety margin Under positive conditions, the deviation of equivalent fill rate - outer diameter - fiber excess length is converged into a controllable continuous trajectory, and the traction speed, vacuum sizing and pump speed micro-correction are coordinated in a predetermined order to prevent underfilling, backflow and geometric jumps from entering the finished product section.

[0052] During speed changes and start-ups / shutdowns of the production line, the equivalent fill rate, outer diameter, and fiber excess length are often out of sync; if each item is adjusted individually, it's easy to experience a pull where the traction has just stabilized when the outer diameter goes out of the frame again. Since the target mass flow rate has already been generated in the previous stage... Equivalent viscosity Safety margin Therefore, it is possible to unify the three quality indicators into the same solution caliber and allow the weights to vary with the safety margin. Automatic allocation prioritizes suppressing geometric jumps when approaching risk boundaries, and pursues tighter fill rate consistency when moving away from risk boundaries.

[0053] First, construct an objective function based on the smoothing norm, and then perform a weighted integration of the deviations between the equivalent fill rate, outer diameter, and fiber excess length within a solution window; the weights vary with the safety margin. The safety boundary is reduced and then increased, thus transforming it into a solution driver; combined with the motion smoothing term, secondary disturbances are avoided by high-frequency small actions.

[0054] The influence relationship between the three targets on the three control variables was then linearized using a sensitivity matrix. A generalized inverse first-order solution was then used to obtain the linkage correction values ​​for traction speed, vacuum calibrating, and pump speed, in conjunction with the head pressure target from the previous stage. With bypass opening This ensures the coordination of pressure and flow.

[0055] Define smoothed norm integral objectives for fill rate deviation, outer diameter deviation, and fiber excess length deviation on a unified time base, and add an action smoothing term to the same expression to form objective quantities that can be stably solved: Among them, the comprehensive objective function The object to be solved is non-negative and is used to uniformly measure the three deviations and motion smoothness; the current time step. Time window length : Time points and solution windows on a unified time axis; Fill rate deviation The difference between the equivalent fill rate and the target fill rate measures the space occupancy error; outer diameter deviation. The difference between the outer diameter and the target outer diameter measures the geometric dimensional error; fiber excess length deviation. The difference between the excess fiber length and the target excess length is used to measure the error in fiber stress and shrinkage trend; smoothing coefficient. :avoid Non-smooth positive constants are small positive numbers used to stabilize the L1 norm approximation; Weighting function , , A non-negative function that varies with safety margin, taking non-negative values, used to adjust the emphasis under different risk levels; in, It is an upper limit constant. Positive bias; to avoid Minimal values ​​lead to uncontrolled weighting. The derivative norm discretization is achieved by summing the absolute values ​​of the forward differences. Reference , and Motion smoothness coefficient : A tradeoff coefficient that limits the rate of change of motion, with a non-negative value; norm of the derivative of the control quantity. : A measure of the norm of the time derivative of the control quantity, with a non-negative value; Control vector : A vector consisting of traction speed, vacuum sizing negative pressure and slight correction of pump speed, with values ​​that are continuous functions within the executable range; Control vector

[0056] in To unify the moments on the timeline; It is piecewise continuous and differentiable (used for the derivative norm term in the objective function).

[0057] To ensure the safety boundary is integrated into the schedule, the weight varies with the safety margin. The changes are set according to the following formula to provide a safety margin. When the weighting is reduced, the weighting of geometry and excess length increases, while the weighting of fill rate is appropriately reduced. Among them, the weight function : No. The project target weight is used to automatically adjust the weight when the safety margin decreases; weight benchmark. : No. The baseline weighting coefficient for each item is set during line construction; safety margin The safety metrics from the previous stage serve as input for weight allocation; positive bias. Small positive numbers that prevent the denominator from approaching zero are small positive numbers; When in use, the three quality indicators are coupled with a unified time base and a unified norm to avoid the strain caused by decentralized adjustments; the weights are automatically adjusted according to the safety margin, so that geometric stability and margin stability are emphasized when approaching the risk boundary, and tighter fill rate consistency is pursued when far from the boundary, so that the actions are based on evidence.

[0058] Furthermore, the head pressure target already released in the previous phase... With bypass opening Under the protection of the system, a linear relationship is established from the three control variables to the three quality indicators, expressed in the form of a sensitivity matrix; then, the control variable linkage correction vector is solved using the generalized inverse first-order solution. Among them, traction speed correction The increase or decrease in traction speed directly affects the excess length and outer diameter of the optical fiber; sizing negative pressure correction. The increase or decrease in vacuum sizing negative pressure directly affects the outer diameter and filling stability; pump speed correction. Slight increases or decreases in pump speed are used to correct the fill rate; gain coefficient Overall stride factor, used to adjust the intensity of the solution output; Generalized inverse of sensitivity matrix The quality deviation is mapped to the generalized inverse matrix of the control quantity correction, and the values ​​are matrix values; it is calculated through singular value decomposition. in, The regularization coefficient is... For identity arrays; identification process: in runtime... Apply small single-variable step jumps one by one and record them. Steady-state and short-time responses, partial derivatives calculated and assembled. It can be implemented immediately; fill rate deviation Outer diameter deviation Fiber excess length deviation The meaning is the same as before; The sensitivity matrix was first identified in a small-amplitude perturbation experiment. (The partial derivatives of the three quality indicators with respect to the three control variables) are obtained through singular value decomposition. After obtaining the linkage correction, according to the safety margin threshold pair , , Apply amplitude cap and target head-on pressure. With bypass opening The current envelope is checked to ensure that the correction will not push the pressure out of the controllable range; finally, the correction amount is superimposed on the current setting to complete a linkage action. Thus, the three control quantities are solved at once, avoiding the delay and coupling amplification caused by repeated steps; the correction amount is checked in accordance with the safety margin and the pressure envelope in front of the head to ensure the unidirectional coordination of pressure-flow-traction-diametering, and to prevent excessive pulling of a single path.

[0059] To ensure the collaborative calculations are on the right track, the measurements or proxy measurements of equivalent fill factor, outer diameter, and fiber excess length must first be standardized. Field measurements of equivalent fill factor exhibit noise variations and need to be merged into a single reading. Direct online measurement of fiber excess length is unavailable for some sections and must be derived using a proxy based on the traction differential speed-tension-cooling process. Furthermore, a clear sequence of safety triggers must be established to prioritize traction and sizing near risk boundaries, with pump speed correction intervening last, avoiding the side effects of forcibly pulling excess length with adhesive.

[0060] First, using the relative reliability of multi-source measurements as coefficients, a fused reading of the equivalent fill rate is constructed and aligned with the outer diameter reading and fiber excess length surrogate on the same time base; this forms a unified bias triplet. Then, a security trigger sequence is defined: when the security margin... If the pressure drops below the threshold, first freeze the traction speed increase, then lower the adjustment boundary of the sizing negative pressure, and finally allow a small correction to the pump speed; when the safety margin is reached... Once it rebounds, release it in the reverse order.

[0061] In capacitive loop, thermal, and micro-pressure differential probes, fusion weights are assigned based on their respective equipment status and historical consistency to obtain a single equivalent fill rate fusion reading. Simultaneously, traction differential speed, traction tension, and cooling history are used to form fiber excess length surrogate quantities, which are then uniformly incorporated into the deviation calculation. Among them: fiber optic redundant length agency At any moment The estimated value is used in the calculation of the deviation triplet; target surplus. Process target, a real number, used to define the reference for excess length deviation; tradeoff coefficient. , , Convert each process quantity into a coefficient for residual length contribution, with a positive value; Cooling temperature : Cooling section temperature history, used to characterize thermal contraction; reference temperature A reference for translating the temperature history, used to define a zero-heat shrinkage reference; traction tension. : Tension reading of the traction section, used to characterize mechanical tension; reference tension Tension reference, used to define a zero-additional-tension reference; traction speed : Traction section speed, used in conjunction with pump speed; proportional coefficient A coefficient for converting pump speed to material throughput speed is calibrated during pipeline construction; pump speed The metering pump speed, together with the traction speed, affects the excess length. The equivalent fill rate fusion weight is dynamically set based on equipment health and short-term consistency, thus suppressing the weight of jump readings; the fiber excess length proxy is calculated according to the above formula, and the required derivatives or integrals are completed on the same time base using trapezoidal quadrature and forward differencing; thus, the excess length deviation is obtained. Together with the equivalent fill rate deviation and the outer diameter deviation, they form a deviation triplet, which is directly used as the input for the collaborative calculation in the aforementioned steps. Thus, multi-source measurements are merged into a single aperture, and the equivalent fill rate reading is stable and reliable; the fiber excess length proxy integrates the thermal, force, and velocity history quantities into a usable curve, solving the problem of lacking direct measurements for the line body.

[0062] To avoid the tug-of-war of patching one end while losing the other near the risk boundary, a clear trigger sequence and limit execution rules are defined: when the safety margin... If the threshold is broken, the upward correction of the traction speed is frozen, and only the downward correction is retained; at the same time, the available range of the sizing negative pressure correction is narrowed so that the outer diameter fluctuation is suppressed first; finally, the pump speed micro-correction is reserved as a minimum step as a backup to avoid relying on adding glue to force the excess length.

[0063] When safety margin Once the pressure rises above the threshold, the action sequence is gradually reversed, restoring the normal co-calculation step size. During execution, all corrections are aligned with the head pressure target. With bypass opening The current envelope is checked, and if it is about to break through the envelope, the action is postponed until the envelope recedes. Therefore, when approaching the risk boundary, the magnitude and sequence of actions are predictable, avoiding local over-adjustment; under the protection of the pressure envelope, the combination of traction, sizing, and pump speed no longer causes additional pressure spikes or drops.

[0064] Step 4: Without changing the safety margin With the overall goal of always being positive, a closed loop of gas content, compliance, failure, and evidence is constructed to ensure that loop anomalies are identified and absorbed in a timely manner, production operations are subject to orderly constraints and can be restored to a stable range, and key trajectories are traced by roll to form deliverable compliance and quality evidence.

[0065] When changing drums, stopping and restarting, or rapidly increasing linear speed, tiny air bubbles or dissolved gases are prone to appear in the rubber compound and circuit, causing fluctuations in density readings and an increase in the driving energy of the metering pump. This manifests as increased circuit compliance and amplified pressure rebound at the front of the machine.

[0066] If gas content and compliance are not assessed online and absorbed in a timely manner, the pre-head pressure target constructed in the second step will be lost. - Bypass opening -Basic back pressure This will result in passive following, leading to delays and multiple overshoots. Therefore, it is necessary to construct two-phase indicators and equivalent bulk modulus on a unified time base and translate them into improved... Tighten , correction Linkage compensation for feedforward phase.

[0067] First, density time series and driving energy time series are simultaneously collected on the mass flow-density-temperature integrated instrument and the pump drive side to calculate the two-phase indication quantity. This indication quantity does not use variance or standard deviation, but forms a multiplicative measure by the ratio of the first total variation of density to the driving energy, thereby capturing the gas-sparse but significant disturbance without amplifying the noise.

[0068] Then, a small pressure-flow rate test is applied within the bypass circulation window, and the equivalent bulk modulus is estimated based on the volumetric flux and pressure response; based on this, it is decided to first raise the pressure. Further restrictions Finally, give A phase-leading compensation sequence is added. The two identification and compensation processes are implemented on the same time base, enabling the third step of collaborative solution to function in environments where compliance is flattened.

[0069] Regarding the synchronous acquisition of density and driving energy, the two-phase indicator is defined as the product of the first-order total variation of density and the driving energy relative to the reference. After compression by a smoothing function, a dimensionless quantity with clear scaling is obtained. When this quantity exceeds a threshold, it is considered that there is a considerable gas-bearing disturbance in the current loop, and a lifting mechanism is preferentially triggered. -limit - Measures to extend bypass circulation: Where: density Integrated instrument panel at all times The density reading is used to reflect the instantaneous density jump caused by gas content; time variable Integral variables : A unified timeline for defining the recognition window; recognition window duration A sliding time window for two-phase identification, covering the typical duration of one bypass cycle; driving energy. The pump side measures the energy required to maintain the current flow, sensing the increase in energy consumption caused by viscoelasticity and air bubbles. Driven energy The acquisition method is as follows: it can be obtained from the motor bus voltage. With current The product is obtained by converting to rated efficiency, that is... , in, Motor efficiency constant (line setting); reference Take the median value of the stable segment of the bypass loop; drive energy reference. Reference energy during line establishment, used for dimensionless conversion; positive bias. : To prevent small positive numbers where the denominator approaches zero; after the density channel is reconstructed into a continuous curve by cubic splines, forward difference is obtained. Then perform absolute value and sliding integral calculations; align the driving energy and density at the same timestamp and substitute them into the above equation to obtain the two-phase indication quantities. When the two-phase indication quantity If the threshold is exceeded, immediately apply the base back pressure. Increase the value by a fixed increment in a stepped manner, and set the upper limit of the bypass opening. Reduce the pressure by a fixed percentage while extending the duration of the bypass loop; when the two-phase indication... If the price falls continuously below the threshold, the aforementioned restrictions will be gradually released in reverse order.

[0070] By capturing sparse and steep perturbations through the first-order total variation of density, and then enhancing reliability with the driving energy ratio, the gas content determination is transformed from a static absolute value to a dynamic transition perception. The two-phase indication avoids the excessive sensitivity of variance and standard deviation to noise, and can also be compared with... , The action is directly linked, shortening the path from recognition to compensation.

[0071] During the bypass circulation phase, a small volumetric flow rate is applied to the metering pump as a trial, and the equivalent bulk modulus of the loop is obtained from the pressure response before the filling head. A lower bulk modulus indicates higher loop compressibility, requiring a higher compression ratio. ,limit ,right The addition of phase-leading superposition processing makes the pressure-flow relationship observed in the main channel closer to the inertial stiffness: Where: equivalent bulk modulus The equivalent bulk modulus of elasticity of the circuit, used to quantify compressibility; effective volume. The equivalent volume between the metering pump, pipeline, and filling head is calibrated during pipeline construction; the initial time... Recognition time The start time and duration of the trial are used to limit the identification segment; Volumetric flow rate The volumetric flow rate reading of the integrated instrument is used to characterize the inflow rate; reference volumetric flow rate. Steady-state volumetric flow rate before the test, used to calculate the net volume increment; head pressure. : Actual pressure measurement in front of the filling head, used to calculate pressure swing amplitude; maximum and minimum value operators , The extreme value is obtained within the identification segment to obtain the pressure swing amplitude; With the bypass circulation remaining unobstructed, a very small volumetric flow rate is added to the metering pump as a trial, and the volumetric flow rate is recorded. With head pressure The response; the numerator of the volume increment is calculated using trapezoidal quadrature, and the denominator of the pressure swing is obtained using the range, thus yielding the equivalent bulk modulus. When the equivalent bulk modulus When the pressure falls below the baseline threshold, immediately adjust the base back pressure. Increasing the scale by one increment will raise the upper limit of the bypass opening. Tighten further and feed forward the pump speed. The updated formula allows for stride length A slight adjustment to the phase-leading configuration allows the main channel to build up pressure ahead of time, thereby offsetting the lag in loop compliance.

[0072] Therefore, the ratio of volume increment to pressure swing amplitude is used to characterize loop stiffness. The identification process does not rely on higher-order statistics and is easy to implement. and , , The stride and phase are systematically linked to form a closed loop of identification-compensation-reset, which significantly compresses the secondary overshoot caused by compliance.

[0073] When the two-phase indication value continues to rise or the equivalent bulk modulus continues to be low, and the safety margin is low... As the boundary approaches, continuing normal collaborative solution will amplify the disturbance, and the risk will escalate from local instability to system mismatch.

[0074] Therefore, a unified threshold function is needed to organize the sequence of operation-alert-degradation-controlled shutdown, and the action limits and recovery conditions should be written as explicit mathematical expressions. Furthermore, verifiable evidence summaries should be generated from the key trajectories across all state transitions, ensuring that each lift... ,limit ,change Adjustment Adjustment All can be traced back.

[0075] Combined with safety margin Two-phase indication With equivalent bulk modulus A threshold function is used to give the transfer trigger value of the four-state machine; when the trigger value drops below zero, it enters a more stringent next state and executes in the following order: freeze traction upward correction - reduce the available range of sizing negative pressure - limit pump speed step - increase base back pressure - extend bypass circulation - controlled shutdown if necessary.

[0076] At the same time, pressure on the head Target quality flow rate Equivalent viscosity Safety margin Bypass opening Basic back pressure traction speed , sizing negative pressure Pump speed Fiber optic spare length agent The entire process is completed, and evidence summaries are generated by volume and archived uniformly.

[0077] The safety margin, two-phase, and compliance terms are combined into a threshold function, which serves as the unified trigger for the four-state machine. When this value is below zero, the process advances to the next state; when it returns to positive and remains there for a certain duration, it reverts to the previous state. Among them, the threshold function : A unified trigger value used for four-state machine transitions, providing a benchmark for the action sequence; safety margin Safety indicators derived from the aforementioned steps; lower safety limit : The minimum allowable safety margin; if the value is below this, the system will enter the next state; two-phase indication quantity. : Recognition value, non-negative; upper limit of two phases : The upper limit of the permissible two-phase index; exceeding this value will lead to the next state; equivalent bulk modulus. : Recognition value, positive; the smaller the value, the greater the compliance; modulus lower limit : The lower limit of the allowable equivalent bulk modulus; below this value, it enters the next state; Minimum operator Choose the smallest of the three; When the threshold function When transitioning from the running state to the alert state, the upward correction component of the traction speed is frozen, allowing only downward correction; if the threshold function... If the pressure remains below zero for a certain period of time, the system enters a degraded state, further reducing the correction range of the sizing negative pressure and increasing the upper limit of the pump speed step. Lower; if If the situation worsens again and falls below a more stringent threshold, the system will enter a controlled shutdown state, with the bypass activated to initiate recirculation, traction gradually reduced to a safe speed, and the temperature set. A steady decline. The relaxed conditions for each state are: And maintain the dwell time, sequentially reverting to the previous state until the running state. All limits are aligned with the head-on pressure target. Envelope verification helps avoid introducing new pressure spikes at the edge of the pullback.

[0078] Thus, the three key risk quantities are combined into a single trigger quantity, eliminating the uncertainty of multiple threshold preemption; the strict order and dwell time rules of the four-state machine make the degradation-stop-reset process controllable and predictable, no longer relying on human experience.

[0079] Key process quantities are segmented by volume, and evidence digest quantities are calculated based on a unified time base to express the consistency of temperature, pressure, flow rate, safety boundary, and action trajectory. To avoid relying on general statistics, a weighted path integral digest quantity is defined to generate a comparable numerical fingerprint for each volume, which is then bound to the work order number and timestamp. Where: Evidence summary quantity : No. The path integral fingerprint corresponding to the volume is used for delivery and traceability; the start and end times of the volume division. : No. The start and end times of a volume are set as an increasing time series value, used to define the volume intervals; temperature. : Process temperature-time function, expressing the thermal history; Head pressure : Pressure-time function before filling the head, representing the pressure path; Target quality flow : The time function of the injected target, expressing the setting change; bypass opening. Bypass valve opening time function, with a value between 0 and 1, representing transient pressure relief action; safety margin. Safety boundary quantity, expressing the dynamics of the safety space; trade-off coefficient. Five path weights, all with positive values; assigned at launch to reflect the priorities within each factory; Using cubic splines, reconstruct each time function within the segmented time period. Differentiate by forward difference, take the absolute value, perform weighted summation, and integrate using a trapezoidal rule to obtain... Simultaneously, the volume number, work order number, and timestamp are written.

[0080] Upon delivery, show The distribution range of qualified test papers in the same batch, as well as the corresponding key trajectory segments (temperature-pressure-flow rate-safety margin-motion curve), are recorded for manual verification. If If the alarm exceeds the factory's alarm range, a check is required to re-examine the preheating-pre-circulation-pre-compression or bypass-back pressure settings.

[0081] Therefore, the evidence summary quantity integrates the intensity of changes in key trajectories into single values, which neither rely on commonly used statistics nor fail to stably present process characteristics; furthermore, the single-value fingerprints bound to volume numbers and timestamps facilitate external audits and client reviews, supporting the generation of type inspection materials.

[0082] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0083] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0084] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0085] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0086] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An adaptive closed-loop control method for water-blocking filling lines in optical cables, characterized in that: include, Collect mass flow rate-density-temperature, pump outlet and filling head pressure, temperature, front edge and equivalent filling rate, outer diameter, traction speed and fiber optic excess length; based on this, estimate the equivalent viscosity, calculate the target mass flow rate and generate a safety margin. Based on the target mass flow rate, the metering pump speed and traction speed are synchronized to construct the target pressure trajectory in front of the head; a micro-bypass and back pressure stabilization are set between the metering pump and the filling head, and the pump speed slope and the maximum opening of the bypass are limited according to the safety margin. With a positive safety margin, the traction speed, vacuum sizing and pump speed are adjusted in conjunction with the deviation of equivalent fill rate, outer diameter and fiber length based on the equivalent fill rate, outer diameter and fiber length deviation, and are checked against the target trajectory of the front pressure. Two-phase indicators are constructed based on density changes and driving energy, and the equivalent bulk modulus is identified by small pressure-flow rate probes, triggering graded limiting and controlled shutdown. Traceability records are generated by summarizing temperature, pressure, mass flow rate, safety margin, and key actions by roll. The two-phase indication is composed of the time accumulation of density change rate and driving energy ratio. The equivalent bulk modulus is identified by small pressure and volumetric flow rate during the micro-bypass circulation stage. When the two trigger the threshold, the base back pressure is increased, the maximum bypass opening is tightened, and the pump speed step and phase are adjusted in sequence. The threshold function is composed of safety margin, two-phase indication quantity and equivalent bulk modulus. The dwell time and transfer conditions are set in the order of operation, warning, degradation and controlled shutdown. An evidence summary is generated at the end of each volume. The summary is archived in association with the volume number, work order number and timestamp.

2. The adaptive closed-loop control method for water-blocking filling lines in optical cables according to claim 1, characterized in that: The mass flow rate, density, temperature, pump outlet and filling head pressure, temperature, front edge and equivalent filling rate, outer diameter, traction speed and fiber excess length are aligned on a unified time base. When changing the mold or specification, the annular gap geometry and density benchmark are checked, and the equivalent viscosity and target mass flow rate are generated by binding according to the work order number.

3. The adaptive closed-loop control method for water-blocking filling lines in optical cables according to claim 2, characterized in that: When generating the safety margin, the exposure amount exceeding the temperature threshold is statistically calculated according to the sliding time window. The equivalent viscosity, filling rate, annular geometry, and attitude angle are combined to form a drip risk index. The remaining amount corresponding to this index is then used to form the safety margin, which is published together with the timestamp to subsequent steps.

4. The adaptive closed-loop control method for water-blocking filling lines in optical cables according to claim 3, characterized in that: The metering pump speed is driven by the target mass flow rate and synchronized with the traction speed. The slope of the pump speed change is limited according to the safety margin. The target trajectory of the front pressure is formed by superimposing the base back pressure, the target mass flow rate and its rate of change. The trajectory provides a reference for bypass and back pressure control under a unified time base.

5. The adaptive closed-loop control method for water-blocking filling lines in optical cables according to claim 4, characterized in that: A micro-bypass is set between the metering pump and the filling head and connected in series with a back pressure regulator. The micro-bypass uses a high-speed proportional valve to divert or recover the flow, and the back pressure regulator maintains the basic back pressure. When the target trajectory of the pressure in front of the head deviates from the actual measurement, the maximum opening of the bypass and the pump speed step are adjusted according to the safety margin, and the pump speed is kept in the same phase as the traction speed.

6. The adaptive closed-loop control method for water-blocking filling lines in optical cables according to claim 5, characterized in that: Before entering the main channel, preheating, pre-circulation and pre-compression are performed in sequence: the loop is raised to the target window according to the temperature setting, and the loop is circulated in the micro-bypass until the equivalent viscosity is stable. Then, the basic back pressure is established by back pressure stabilization. After completion, the main channel is opened and the micro-bypass is kept at the reference opening and ready.

7. The adaptive closed-loop control method for water-blocking filling lines in optical cables according to claim 6, characterized in that: Using the equivalent fill rate, outer diameter, and fiber excess length as a unified target, the linkage between traction speed, vacuum sizing, and pump speed micro-correction is obtained based on the sensitivity matrix and the generalized inverse first solution. The traction speed and vacuum sizing are executed first, followed by the pump speed micro-correction, and the results are checked against the target trajectory of the front pressure.

8. The adaptive closed-loop control method for water-blocking filling lines in optical cables according to claim 7, characterized in that: The equivalent fill rate is obtained by weighting and integrating measurements from capacitive loop, thermal, or micro-pressure differential probes according to health status. The fiber excess length is composed of traction differential speed, traction tension, and cooling process as proxy quantities. The deviation of the three is calculated in time base and used as input for solving the linkage quantity.

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