Composite insulator umbrella skirt silicone rubber mixing control system and processing method thereof

Abstract

The invention discloses a composite insulator umbrella skirt silicone rubber mixing control system and a processing method thereof. Relates to the silicone rubber mixing field. Comprising a multi-material grading feeding unit, and the multi-material grading feeding unit comprises a powder feeding module and an oil injection module; the rubber material pretreatment and delivery unit comprises a rubber material belt weigher and a rubber compound conveyor; the linkage control unit comprises an upper computer and a lower computer, the upper computer is electrically connected with the lower computer through an industrial Ethernet, and the upper computer, the multi-material grading feeding unit and the sizing material pretreatment and delivery unit form a closed-loop control loop. The linkage control unit is used for effectively coordinating the weighing process of the multi-material grading feeding unit, the conveying process of the sizing material pretreatment and feeding unit and the mixing process of the kneading machine, meanwhile, manual batching errors are avoided, and the overall production efficiency is improved.

Description

TECHNICAL FIELD

[0001] The application relates to the field of mixing of silicone rubber, in particular to a composite insulator umbrella skirt silicone rubber mixing control system and a processing method thereof. BACKGROUND

[0002] With the continuous development of the electric power industry, the performance requirements for insulating materials are also increasing. The umbrella skirt part of the composite insulator adopts silicone rubber as the main material, which can effectively guarantee the stable operation of the power system due to its good insulation and weather resistance. The production of silicone rubber involves multiple complex links, and the stability of its performance is directly related to the quality and service life of the composite insulator, which makes the production technology of silicone rubber one of the focuses of the electric power industry.

[0003] In the production process of the composite insulator umbrella skirt silicone rubber, batching, mixing and conveying are three key steps. In the traditional production method, the batching is usually manually accurate weighing and mixing of various raw materials by workers according to the formula. The mixing process is generally mixing various materials by using ordinary mixing equipment through specific mechanical means. The conveying link is to use conventional conveying equipment to send the silicone rubber into the mold or the next process after mixing is completed.

[0004] However, there is a lack of effective linkage control among the three key links of batching, mixing and conveying, which leads to unreasonable production task switching time and long task switching gap, thereby increasing the production preparation time and greatly reducing the overall production efficiency. SUMMARY

[0005] In order to overcome the deficiencies of the prior art, the application provides a composite insulator umbrella skirt silicone rubber mixing control system and a processing method thereof.

[0006] Firstly, the application provides a composite insulator umbrella skirt silicone rubber mixing control system, which adopts the following technical scheme: A composite insulator umbrella skirt silicone rubber mixing control system, characterized in that it comprises: A multi-material grading feeding unit, which comprises a powder feeding module and an oil injection module; A rubber material pretreatment and delivery unit, which comprises a rubber material belt scale and a mixed rubber conveyor; A linkage control unit, which comprises an upper computer and a lower computer, the upper computer is electrically connected with the lower computer through an industrial Ethernet, and forms a closed-loop control circuit with the multi-material grading feeding unit and the rubber material pretreatment and delivery unit, and is used for synchronously coordinating the weighing process of the multi-material grading feeding unit, the conveying process of the rubber material pretreatment and delivery unit and the mixing process of the kneader.

[0007] Optionally, the powder feeding template is used for feeding white carbon black powder and small powder, so the powder feeding module comprises an unpacking machine, a daily hopper, a screw feeder and a powder scale, the unpacking end of the unpacking machine is located above the input end of the screw feeder, the output end of the screw feeder is located above the feeding end of the daily hopper, and the discharging end of the daily hopper is in communication with the kneader.

[0008] Optionally, the oil quantitative injection module comprises an intermediate oil storage tank and an oil scale, and the oil storage tank is in communication with the kneader.

[0009] Optionally, the powder feeding module further comprises a dust collector and a pneumatic arch breaker, the dust collector is used for sucking and removing dust generated during unpacking of the unpacking machine, and the pneumatic arch breaker can send pulse airflow into the daily hopper.

[0010] Optionally, the rubber compound belt scale is provided with an anti-sticking conveying belt, the length of the rubber compound conveyor is greater than or equal to 7 meters, and the inner wall is provided with a Teflon coating.

[0011] Optionally, the linkage control unit comprises an upper computer, a lower computer and a field control substation, the upper computer is provided with industrial configuration software, supports mixing process editing and permission management, the lower computer adopts a programmable logic controller, the field control substation is provided with an industrial touch screen and low-voltage electrical appliances, and the lower computer is in communication connection with the multi-material grading feeding unit and the rubber compound pretreatment and feeding unit through an industrial Ethernet.

[0012] Optionally, the multi-material grading feeding unit, the rubber compound pretreatment and feeding unit and the kneader are connected through automatic valves, and the linkage control unit controls the opening and closing of the automatic valves.

[0013] Secondly, the application also provides a composite insulator umbrella skirt silicone rubber mixing processing method, which is realized by adopting the following technical scheme: A composite insulator umbrella skirt silicone rubber mixing processing method applied to a composite insulator umbrella skirt silicone rubber mixing control system, comprising the following steps: S1: system power-on self-checking, importing a production formula through an upper computer, the formula containing up to 50 mixing process steps, the process steps including kneader action steps, time-temperature-power combination waiting steps and speed modification steps; S2: after white carbon black powder and small powder are unpacked by an unpacking machine, the white carbon black powder and the small powder are stored in a daily hopper, oil is injected into an intermediate oil storage tank through an oil pump or a manual oil injection port, and rubber compound is conveyed to a rubber compound belt scale through a rubber compound conveyor; S3: the upper computer sends a production task to a lower computer, and after white carbon black, small powder, oil and rubber compound are weighed according to the formula, the white carbon black, the small powder, the oil and the rubber compound are automatically fed into the kneader; S4: The kneader mixes according to the preset process parameters. During the process, temperature, pressure and current data are collected in real time by sensors. When weighing error, equipment failure or overheating occurs, an audible and visual alarm is triggered and the alarm details are recorded. S5: After the rubber compound is mixed, it is conveyed to the filter via a conveyor. The host computer automatically records the material consumption, production time, operators, and equipment status data, and generates printable reports and real-time curves. S6: During the production process, the task order can be adjusted, the number of production vehicles can be increased or decreased, or tasks can be deleted via the host computer. It also supports remote monitoring of equipment operation status and fault diagnosis.

[0014] In summary, this application includes the following beneficial technical effects: 1. The linkage control unit forms a closed-loop control circuit through the host computer and the slave computer, so that the weighing process of the multi-material graded feeding unit, the conveying process of the rubber pretreatment and feeding unit, and the mixing process of the kneader are synchronized and coordinated. This avoids the problem of unreasonable production task switching time caused by the lack of linkage control in the three links of batching, mixing and conveying in the existing technology, and effectively reduces the task switching gap.

[0015] 2. The multi-material grading and feeding unit includes a powder feeding module and an oil injection module. It can be operated precisely by automated equipment to avoid human error caused by manual batching. It ensures that various raw materials such as silica powder, small powder, and oil are accurately weighed and mixed according to the formula, thereby ensuring the stability of silicone rubber performance.

[0016] 3. The linkage control unit effectively coordinates the weighing of the multi-material graded feeding unit, the pretreatment of the rubber compound and the conveying of the feeding unit and the mixing process of the kneader, while avoiding errors caused by manual batching and improving overall production efficiency. Attached Figure Description

[0017] Fig. 1 This is a schematic diagram of the structure of this application; Fig. 2 This is a structural diagram of the powder feeding module and the oil injection module; Fig. 3 This is a reference diagram showing the position and status of the kneader and filter. In the diagram: 1. Multi-material grading and feeding unit; 11. Unpacking machine; 12. Daily storage hopper; 13. Screw feeder; 14. Intermediate oil storage tank; 15. Automatic valve; 2. Rubber compound pretreatment and feeding unit; 21. Rubber compound belt scale; 22. Compound conveyor; 3. Kneader; 4. Filter press; 40. Conveyor. Detailed Implementation

[0018] The present application will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0019] like Figs. 1-3 As shown in the figure, this embodiment discloses a composite insulator skirt silicone rubber mixing control system.

[0020] A composite insulator skirt silicone rubber mixing control system includes a multi-material grading and feeding unit 1, a rubber pretreatment and feeding unit 2, and a linkage control unit. The linkage control unit forms a closed-loop control loop with the multi-material grading and feeding unit 1 and the rubber pretreatment and feeding unit 2 via an industrial Ethernet. It can synchronously coordinate the weighing process of the multi-material grading and feeding unit 1, the conveying process of the rubber pretreatment and feeding unit 2, and the mixing process of the kneader 3, thereby improving production efficiency and reducing the gap between production tasks.

[0021] Specifically, the multi-material grading and feeding unit 1 includes a powder feeding module and an oil injection module. The powder feeding module is used to feed silica powder and small powders, and includes an unpacking machine 11, a daily storage hopper 12, a screw feeder 13, and a powder scale. The unpacking machine 11 generally uses mechanical unpacking equipment, which opens the packaged powder bags. It has a high degree of automation and can reduce errors caused by manual operation. The discharge end of the unpacking machine 11 is located above the input end of the screw feeder 13, so that the powder can fall smoothly into the screw feeder 13 after exiting the unpacking machine 11. The screw feeder 13 is constructed as a conveying pipe with spiral blades, which transport the powder to the daily storage hopper 12 by rotating the spiral blades. The daily storage hopper 12 is used to temporarily store the powder, and its discharge end is connected to the kneader 3. The powder scale is used to accurately weigh the powder, and an electronic weighing scale can be used, which has the characteristics of high precision. In addition, the powder feeding module also includes a dust collector and a pneumatic arch breaker. The dust collector can be a bag filter, and its function is to remove the dust generated during the unpacking process of the unpacking machine 11, maintaining a clean working environment. The pneumatic arch breaker can deliver pulsed airflow into the daily storage hopper 12 to prevent powder from clumping inside the hopper and ensure smooth powder feeding.

[0022] The oil injection module includes an intermediate oil storage tank 14 and an oil scale. The intermediate oil storage tank 14 is a container used to store the oil, typically made of stainless steel for corrosion resistance. The intermediate oil storage tank 14 is connected to the kneader 3, and the oil is transported to the kneader 3 via pipeline. The oil scale is used to accurately weigh the oil dosage; a flow scale can be used.

[0023] The combined logic of the multi-material grading and feeding unit 1 is as follows: the unpacking machine 11 first unpacks the powder, and then the screw feeder 13 conveys the powder to the daily storage hopper 12. During this process, the powder scale weighs the powder, while the dust collector removes dust and the pneumatic arch breaker prevents the powder from clumping. The oil is first stored in the intermediate oil storage tank 14, and after being weighed by the oil scale, it is injected into the kneader 3. This combination enables the grading and precise weighing of multiple materials, providing an accurate raw material ratio for subsequent mixing.

[0024] The rubber compound pretreatment and feeding unit 2 includes a rubber compound belt scale 21 and a compound conveyor 22. The rubber compound belt scale 21 is equipped with an anti-stick conveyor belt to effectively prevent rubber compound from sticking together. The rubber compound belt scale 21 is used to weigh the rubber compound, ensuring the accurate amount of rubber compound fed into the kneader 3. The compound conveyor 22 is ≥7 meters long and has a Teflon coating on its inner wall. The Teflon coating has a low coefficient of friction and non-stick properties, allowing the rubber compound to pass smoothly during transport and reducing residue.

[0025] The combination logic of the rubber pretreatment and feeding unit 2 is that the rubber conveyor 22 transports the rubber to the rubber belt scale 21, the rubber belt scale 21 weighs the rubber, and then the weighed rubber is transported to the kneader 3. This combination can realize the pretreatment and accurate feeding of the rubber.

[0026] The linkage control unit includes a host computer, slave computers, and field control substations. The host computer is equipped with industrial configuration software, supporting mixing process editing and access control. This software visually displays various parameters and equipment statuses during production, facilitating monitoring and management by operators. The host computer typically uses an industrial computer. The slave computers employ programmable logic controllers (PLCs), characterized by high reliability and flexible programming, enabling control of individual devices according to preset programs. The field control substations are equipped with industrial touchscreens and low-voltage electrical components. The touchscreens facilitate on-site operation and parameter setting by operators. The slave computers communicate with the multi-material grading and feeding unit 1 and the rubber pretreatment and feeding unit 2 via industrial Ethernet, enabling real-time information transmission and control.

[0027] The combined logic of the linkage control unit is as follows: the host computer sends commands to the slave computer via industrial Ethernet, and the slave computer controls the operation of the multi-material grading and feeding unit 1 and the adhesive pretreatment and feeding unit 2 according to the commands. Simultaneously, the field control substation can perform on-site operation and monitoring. This combination enables centralized control and coordinated management of the entire production process. Furthermore, the multi-material grading and feeding unit 1, the adhesive pretreatment and feeding unit 2, and the kneader 3 are connected via an automatic valve 15. The linkage control unit controls the opening and closing of the automatic valve 15 to ensure that materials are fed into the kneader 3 in a predetermined order and quantity.

[0028] The implementation principle of this embodiment is as follows: the multi-material grading and feeding unit 1 realizes the accurate weighing and grading of various materials, the rubber pretreatment and feeding unit 2 realizes the accurate feeding of rubber, and the linkage control unit realizes the coordinated work and centralized control between the units. Through the control of the closed-loop control circuit and the automatic valve 15, the production efficiency can be effectively improved, the gap between production tasks can be reduced, the production process can be optimized, and the degree of automation and product quality can be improved.

[0029] This embodiment also discloses a method for compounding and processing silicone rubber for composite insulator skirts.

[0030] A method for compounding and processing silicone rubber for composite insulator skirts includes the following steps: S1: The system performs a power-on self-test and imports the production recipe via the host computer. The recipe contains up to 50 mixing process steps, including three kneading machine action steps, a time-temperature-power combination waiting step, and a speed modification step. During the system power-on self-test, the host computer checks the connection status of each device and the working status of the sensors. When importing the production recipe, the operator only needs to select the corresponding recipe file in the industrial configuration software to complete the import.

[0031] S2: After being unpacked by the unpacker 11, the silica powder and small powders are stored in the daily storage hopper 12. The oil is injected into the intermediate oil storage tank 14 through the oil pump or the manual oil pouring port. The rubber compound is conveyed to the rubber compound belt scale 21 by the rubber compound conveyor 22. The unpacker 11 opens the powder bags, and the powder falls into the screw feeder 13, and is then conveyed to the daily storage hopper 12. The oil can be automatically injected into the intermediate oil storage tank 14 by the oil pump, or it can be poured in through the manual oil pouring port. The rubber compound is conveyed to the rubber compound belt scale 21 by the rubber compound conveyor 22.

[0032] S3: The host computer sends production tasks to the slave computer. Silica, small powders, oils, and adhesives are weighed according to the formula and automatically fed into the kneader 3. The host computer generates production tasks based on the imported formula and sends them to the slave computer via industrial Ethernet. The slave computer controls the powder scale, oil scale, and adhesive belt scale 21 to accurately weigh various materials, and then controls the automatic valve 15 to open, allowing the materials to be fed into the kneader 3.

[0033] S4: Kneader 3 mixes materials according to preset process parameters. During the process, sensors collect temperature, pressure, and current data in real time. If weighing errors, equipment malfunctions, or overheating occur, an audible and visual alarm is triggered, and alarm details are recorded. The sensors feed back the collected temperature, pressure, and current data to the lower and upper computers. In case of any abnormality, the audible and visual alarm will sound, and the upper computer will record detailed alarm information for subsequent troubleshooting and analysis.

[0034] S5: After mixing, the rubber compound is conveyed to the filter machine 4 via conveyor 40. The host computer automatically records material consumption, production time, operator information, and equipment status data, generating printable reports and real-time curves. The mixed rubber compound is then conveyed to the filter machine 4 via conveyor 40 for filtration. The host computer automatically records various data during the production process and generates reports and real-time curves, facilitating production management personnel to statistically analyze the production situation.

[0035] S6: During production, the task sequence, number of production vehicles, or task deletion can be adjusted via a host computer, and remote monitoring of equipment operation status and fault diagnosis are supported. Operators can adjust production tasks through the host computer according to the actual situation during production. At the same time, through the remote monitoring function, managers can remotely understand the equipment operation status and fault conditions anytime and anywhere, and make timely decisions.

[0036] The implementation principle of this embodiment is as follows: through the collaborative work of various units of the system, production is carried out according to preset process steps, realizing fully automated control from raw material input to finished product output, thereby improving production efficiency and product quality. Simultaneously, real-time data acquisition and alarm functions can promptly detect problems in the production process, ensuring production stability. The recording and analysis functions of production data help enterprises with production management and decision-making.

[0037] The above embodiments are merely preferred embodiments of this application and should not be construed as limiting the scope of protection of this application. Any non-substantial changes and substitutions made by those skilled in the art based on this application shall fall within the scope of protection claimed by this application.

Claims

1. A composite insulator skirt silicone rubber compounding control system, characterized in that, include: A multi-material graded feeding unit (1) is provided, which includes a powder feeding module and an oil injection module. The rubber pretreatment and feeding unit (2) includes a rubber belt scale (21) and a compound conveyor (22); The linkage control unit includes a host computer and a slave computer. The host computer is electrically connected to the slave computer via an industrial Ethernet and forms a closed-loop control loop with the multi-material grading and feeding unit (1) and the rubber pretreatment and feeding unit (2) to synchronously coordinate the weighing process of the multi-material grading and feeding unit (1), the conveying process of the rubber pretreatment and feeding unit (2), and the mixing process of the kneader (3).

2. The composite insulator skirt silicone rubber mixing control system according to claim 1, characterized in that, The powder feeding template is used to feed silica powder and small powders. Therefore, the powder feeding module includes an unpacking machine (11), a daily storage hopper (12), a screw feeder (13), and a powder scale. The unpacking machine (11) has its discharge end above the input end of the screw feeder (13), and the output end of the screw feeder (13) is above the feed end of the daily storage hopper (12). The discharge end of the daily storage hopper (12) is connected to the kneader (3).

3. The composite insulator skirt silicone rubber mixing control system according to claim 2, characterized in that, The oil metering injection module includes an intermediate oil storage tank (14) and an oil scale, and the oil storage tank is connected to the kneader (3).

4. The composite insulator skirt silicone rubber mixing control system according to claim 3, characterized in that, The powder feeding module also includes a dust collector and a pneumatic arch breaker. The dust collector is used to remove the dust generated when the unpacking machine (11) unpacks the powder, and the pneumatic arch breaker can deliver pulsed airflow into the daily storage hopper (12).

5. A composite insulator skirt silicone rubber mixing control system according to claim 3, characterized in that, The rubber belt scale (21) is equipped with an anti-stick conveyor belt, and the rubber compound conveyor (22) has a length of ≥7 meters and an inner wall coated with Teflon.

6. The composite insulator skirt silicone rubber mixing control system according to claim 4, characterized in that, The linkage control unit includes a host computer, a slave computer, and a field control substation. The host computer is equipped with industrial configuration software, which supports mixing process editing and permission management. The slave computer adopts a programmable logic controller. The field control substation is equipped with an industrial touch screen and low-voltage electrical appliances. The slave computer is connected to the multi-material grading feeding unit (1) and the rubber pretreatment and feeding unit (2) via industrial Ethernet.

7. A composite insulator skirt silicone rubber mixing control system according to claim 6, characterized in that, The multi-material grading and feeding unit (1), the rubber pretreatment and feeding unit (2), and the kneader (3) are connected by an automatic valve (15), and the linkage control unit controls the opening and closing of the automatic valve (15).

8. A method for compounding and processing silicone rubber for composite insulator skirts, applied to the composite insulator skirt silicone rubber compounding control system described in claim 6, characterized in that, Includes the following steps: S1: The system performs a power-on self-test and imports the production formula through the host computer. The formula contains up to 50 mixing process steps, including the kneader (3) action step, the time-temperature-power combination waiting step, and the speed modification step. S2: The white carbon black powder and small powder are unpacked by the unpacking machine (11) and stored in the daily storage hopper (12). The oil is injected into the intermediate oil storage tank (14) through the oil pump or manual oil pouring port. The rubber is transported to the rubber belt scale (21) by the rubber mixing conveyor (22). S3: The host computer sends the production task to the slave computer. The silica, powder, oil and rubber are weighed according to the formula and automatically put into the kneader (3). S4: Kneader (3) mixes according to preset process parameters. During the process, temperature, pressure and current data are collected in real time by sensors. When weighing error, equipment failure or overheating occurs, an audible and visual alarm is triggered and the alarm details are recorded. S5: After the rubber compound is mixed, it is conveyed to the filter machine (4) through the conveyor (40). The host computer automatically records the material consumption, production time, operators, and equipment status data, and generates printable reports and real-time curves. S6: During the production process, the task order can be adjusted, the number of production vehicles can be increased or decreased, or tasks can be deleted via the host computer. It also supports remote monitoring of equipment operation status and fault diagnosis.

Images