Forming mold based on saddle production and forming assembly line thereof
By using adaptive injection technology with vacuum degree change rate control and temperature compensation, combined with dynamic scheduling of digital twin models, the problems of inconsistent fabric bonding and uneven foaming material in bicycle saddle production have been solved, achieving a highly efficient and stable production process.
Patent Information
- Application Number
- CN202610057900.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-16
- Publication Date
- 2026-03-03
AI Technical Summary
Existing bicycle saddle production equipment cannot detect the fabric fit during the vacuuming process. The amount of foam material injected is affected by the ambient temperature, resulting in inconsistent product size and weight, and low production efficiency.
By employing state-sensing control based on vacuum degree change rate and adaptive filling compensation based on ambient temperature, combined with a digital twin model for dynamic scheduling, we can ensure consistent fabric bonding quality and uniform foam filling.
It improved product quality consistency, reduced defect rates, and increased production efficiency and equipment utilization.
Smart Images
Figure CN121589964A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of bicycle saddle manufacturing technology, and more particularly to a molding die and molding production line based on saddle production. Background Technology
[0002] Traditional bicycle saddle production, especially for models covered in leather or synthetic fabrics, typically employs in-mold foaming. A typical molding die includes a saddle-shaped mold frame with micropores. The fabric is pre-fitted through vacuuming, then foam material is injected, and the mold is closed to set the shape. Current production lines often install multiple such molds on a circular assembly line, sequentially passing them through stations for feeding, injection, curing, and unloading.
[0003] However, existing technologies have significant drawbacks: First, the vacuuming process is typically based on fixed time control, making it impossible to determine whether the fabric is fully bonded. Different batches and materials of fabric vary in breathability and elasticity, and a fixed vacuuming time can easily lead to under-vacuuming (resulting in poor bonding and wrinkles) or over-vacuuming (wasting energy and even damaging the fabric). Second, the injection amount of foaming material is usually preset, but the flowability of foaming material is significantly affected by ambient temperature. A fixed injection amount can lead to insufficient filling or overflow during temperature fluctuations, affecting the consistency of product size and weight. Furthermore, production lines generally use fixed rotation cycles. When a mold is delayed or a process step (such as vacuuming) is not completed, the entire production line is forced to wait, or unfinished products flow into the next process, reducing overall efficiency and increasing the scrap rate. In addition, the above processes heavily rely on the experience and judgment of operators, resulting in unstable production quality and making it difficult to achieve large-scale, efficient production.
[0004] Therefore, to address the above issues, a molding die and its molding production line based on saddle production are proposed. By introducing state-sensing control based on the rate of change of vacuum degree and combining it with adaptive injection compensation based on ambient temperature, the equipment can adapt to the process state and improve the quality of the finished product. Summary of the Invention
[0005] To overcome the problems of existing bicycle saddle production equipment, such as the vacuuming process being based on fixed time control, making it impossible to sense whether the fabric has fully adhered, and the foam injection amount being usually a preset value, but the flowability of the foam is significantly affected by the ambient temperature, and a fixed injection amount can lead to insufficient filling or overflow when the temperature fluctuates, affecting the consistency of product size and weight.
[0006] The technical solution of this invention is as follows: a molding die based on saddle production, comprising a die base, a saddle mold frame, a die top plate, and a locking mechanism. The saddle mold frame is shaped like a bicycle saddle and is embedded inside the die base. A cavity is formed between the bottom of the saddle mold frame and the inner bottom surface of the die base. Microholes communicating with the cavity are opened on the saddle mold frame. An air pipe communicating with the cavity is provided on the outer side of the die base. The edge of the die top plate is hinged to the edge of the die base. The die top plate includes a coaxially rotatable pressing frame and a pressing plate; it also includes: The control system is configured to communicate with an air pump connected to the air pipe. The control system is further configured to: when the cavity is evacuated by the air pump, calculate the vacuum change rate based on the real-time change data of the vacuum degree in the air pipe; when the vacuum change rate is detected to change from the initial rapid decline state to a flat state below the preset threshold, determine that the saddle leather fabric has adhered to the inner wall of the saddle mold frame, and control the air pump to stop or switch to the pressure holding mode.
[0007] Preferably, the control system is configured to: indirectly estimate the vacuum level in the air tube by monitoring the operating current of the air pump, and calculate the vacuum level change rate based on the curve of vacuum level change over time.
[0008] Preferably, the control system is further configured to: record the time taken for the vacuum change rate to decrease from the initial value to the preset threshold, and compare the time with a preset standard time range; if the time exceeds the standard time range, it is determined that there is an abnormal fabric placement or air leakage fault, and an alarm signal is triggered.
[0009] Preferably, the control system is also communicatively connected to an injection device that injects foaming material into the saddle mold frame. The control system is configured to: collect ambient temperature data and dynamically adjust the injection parameters of the injection equipment according to a pre-stored injection volume-temperature compensation relationship model, so as to compensate for the difference in the flowability of the foaming material caused by changes in ambient temperature.
[0010] Preferably, the control system is configured to: continuously record the actual ambient temperature, adjusted injection parameters, and corresponding mold identifier for each production process; and iteratively optimize the parameters in the injection volume-temperature compensation relationship model based on the subsequently obtained molding quality feedback information of the corresponding product in the mold.
[0011] A molding production line based on saddle production includes: Multiple molding dies; A circular conveyor, wherein the plurality of forming molds are arranged circumferentially along its circular conveyor frame; Multiple workstations are arranged along the conveying path of the circular conveyor, including at least a material feeding workstation, a material injection workstation, and a material removal workstation; The central controller is communicatively connected to the drive unit of the circular conveyor and the control system of each forming mold; The central controller is configured to: establish and maintain a digital twin model for each molding die, and synchronize the process completion status of the corresponding die at each workstation in real time; based on the digital twin model status of all molding dies, dynamically decide the rotation timing and dwell time of the circular conveyor through a fuzzy logic algorithm.
[0012] Preferably, the process completion status includes at least: the completion status of the vacuuming process at the material feeding station, the completion status of the foaming material injection at the material injection station, and the remaining molding time calculated after the material injection is completed.
[0013] Preferably, the central controller is configured to execute the following dynamic scheduling rules: If the digital twin models of the forming molds exceeding the set proportion are all displayed as "waiting for circulation", then the circular conveyor is controlled to shorten the dwell time in the current cycle. If the digital twin model of any molding die located at a critical workstation shows that its current process has not met the completion conditions, the circular conveyor is controlled to extend the dwell time at the current workstation until the mold process is completed or the maximum waiting time limit is reached.
[0014] Preferably, the central controller is configured to: when the digital twin model of a molding die receives a fault alarm signal from its control system, mark the die as an abnormal die; in subsequent scheduling, control the ring conveyor to make the abnormal die skip the injection station and directly transfer it to the designated maintenance station or material picking station.
[0015] Preferably, the feeding station and / or unloading station are equipped with a vision assist unit; The visual assistance unit includes an image acquisition device and a prompting device. The image acquisition device is configured to acquire images of the operation area. The central controller or a local processing unit is configured to analyze the images to determine whether the fabric is placed correctly during feeding or whether the workpiece has been completely removed during retrieval. The prompting device provides guidance or warning information to the operator.
[0016] The beneficial effects of this invention are: 1. This invention introduces state-sensing control based on vacuum degree change rate and adaptive injection compensation combined with ambient temperature, enabling the equipment to adapt to different process states. This fundamentally ensures the consistency of bonding quality and uniformity of foam filling in the pre-formed saddle fabric, and significantly reduces the product defect rate caused by the solidification of process parameters. 2. This invention uses flexible dynamic scheduling to make the production line's rhythm no longer a fixed bottleneck, but to be flexibly adjusted according to the actual production pace. This ensures sufficient processing time for each product while maximizing equipment utilization and overall production efficiency. Attached Figure Description
[0017] Figure 1 The diagram shown is a first three-dimensional structural schematic of the molding die based on saddle production according to the present invention; Figure 2 The diagram shown is a second three-dimensional structural schematic of the molding die based on saddle production according to the present invention; Figure 3 The diagram shown is a partial structural schematic of the molding die for saddle production according to the present invention; Figure 4 The diagram shown is a cross-sectional view of the molding die for saddle production according to the present invention. Figure 5 The diagram shown is a schematic representation of the circular conveyor system for the molding production line based on saddle production according to the present invention. Explanation of reference numerals in the attached drawings: 1. Mold base; 2. Saddle mold frame; 3. Mold top plate; 4. Locking mechanism; 5. Cavity; 6. Air pipe; 7. Air pump; 21. Microhole; 31. Pressing frame; 32. Pressing plate; 8. Circular conveyor. Detailed Implementation
[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments.
[0019] Example 1 Please see Figure 1-2 This invention provides an embodiment: a molding die based on saddle production, including a die base 1, a saddle mold frame 2, a die top plate 3, and a locking mechanism 4. The saddle mold frame 2 is shaped like a bicycle saddle and is embedded inside the die base 1. A cavity 5 is formed between the bottom of the saddle mold frame 2 and the inner bottom surface of the die base 1. A microhole 21 communicating with the cavity 5 is provided on the saddle mold frame 2. An air pipe 6 communicating with the cavity 5 is provided on the outer side of the die base 1. The edge of the die top plate 3 is hinged to the edge of the die base 1. The die top plate 3 includes a coaxially rotatable pressing frame 31 and a pressing plate 32; it also includes: The control system is configured to communicate with the air pump 7 connected to the air pipe 6; The control system is further configured to calculate the vacuum degree change rate based on the real-time change data of the vacuum degree in the air pipe 6 when evacuating the cavity 5 through the air pump 7; when it is monitored that the vacuum degree change rate changes from the initial rapid decline state to a gentle state lower than the preset threshold, it is determined that the saddle leather fabric has been adhered to the inner wall surface of the saddle mold 2, and the air pump 7 is controlled to stop or switch to the pressure maintaining mode.
[0020] Furthermore, the control system is configured to indirectly infer the vacuum degree in the air pipe 6 by monitoring the working current of the air pump 7, and calculate the vacuum degree change rate based on the curve of the vacuum degree changing with time.
[0021] Specifically, in the control system, the monitoring of the vacuum degree can be directly achieved by a pressure sensor installed on the air pipe 6, or a low-cost indirect solution can be adopted - monitoring the working current of the air pump 7; when the air pump 7 is under a constant load, there is a strong correlation between its working current and the outlet resistance (i.e., the vacuum degree); the system obtains the current-vacuum degree correspondence relationship through calibration, so as to infer the vacuum degree in real time; by plotting the curve of the vacuum degree changing with time and calculating its first derivative (i.e., the change rate), the system can accurately capture the inflection point where the curve slope suddenly decreases; this inflection point indicates that the gas in the cavity 5 has been basically evacuated, the gap between the fabric and the mold has been eliminated, and the air mainly slowly discharges through the micropores 21 of the fabric. At this time, the change rate is significantly reduced; the system presets a slope threshold close to zero, and when it is detected that the change rate is lower than this threshold, a fitting completion instruction is issued; thus, the process end point is directly linked to the physical state, eliminating the quality fluctuations caused by material differences.
[0022] Furthermore, the control system is also configured to record the duration experienced by the vacuum degree change rate from the initial value to the preset threshold, and compare this duration with the preset standard duration range; if the duration exceeds the standard duration range, it is determined that there is an abnormal fabric placement or a leakage fault, and an alarm signal is triggered.
[0023] Specifically, the system not only judges the inflection point, but also records the duration T experienced from the start of vacuum pumping to reaching the inflection point; a reasonable duration range [T_min, T_max] measured according to the standard fabric is pre-stored in the system; if the measured duration T < T_min, it may indicate that the fabric is not placed flat, there are large gaps resulting in too fast air extraction, or there is a leak in the vacuum system; if T > T_max, it may mean that the air permeability of the fabric is too poor or the micropores 21 are blocked; the system will trigger an audible and visual alarm accordingly, and can mark this mold as abnormal and notify the operator to check; thus, online monitoring and fault warning of the pre-operation (material placement) and the state of the mold itself are achieved.
[0024] Furthermore, the control system is also communicatively connected to a feeding device that injects foaming material into the saddle mold 2; The control system is configured to collect ambient temperature data and dynamically adjust the injection parameters of the injection equipment according to the pre-stored injection volume-temperature compensation relationship model to compensate for the difference in the flowability of the foaming material caused by changes in ambient temperature.
[0025] Furthermore, the control system is configured to continuously record the actual ambient temperature, adjusted injection parameters, and corresponding mold identifier for each production process; and based on the subsequent obtained molding quality feedback information of the corresponding product in the mold, iteratively optimize the parameters in the injection volume-temperature compensation relationship model.
[0026] Specifically, the control system is also linked to the injection equipment; the system has a built-in ambient temperature sensor and stores an "injection volume-temperature" compensation model; this model describes the correction relationship between the valve opening time (or pump stroke) of the injection equipment and temperature changes in order to achieve the same filling volume (for example, for every 5°C decrease in temperature, the injection time needs to be increased by 5% to compensate for the decrease in fluidity); before production, the system reads the real-time temperature, automatically calculates and sends the adjusted injection parameters to the injection equipment; furthermore, the system has online learning capabilities; after each production run, the final product quality assessment of that batch of molds (such as through weighing or dimensional inspection) can be fed back to the system; if the feedback indicates that the filling effect deviates from expectations, the system can automatically fine-tune the coefficients in the compensation model, so that the model can adapt to changes in the foaming material formula or the aging drift of the equipment, and maintain long-term accuracy.
[0027] A molding production line based on saddle production includes: Multiple molding dies; 8. A ring conveyor equipment, with multiple forming molds arranged circumferentially along its ring conveyor frame; Multiple workstations are set along the conveying path of the circular conveyor 8, including at least a feeding workstation, a filling workstation, and a picking workstation; The central controller is connected in communication with the drive unit of the circular conveyor 8 and the control system of each forming mold; The central controller is configured to: establish and maintain a digital twin model for each molding die; the digital twin model synchronizes the process completion status of the corresponding die at each workstation in real time; based on the status of the digital twin models of all molding dies, the rotation timing and dwell time of the circular conveyor 8 are dynamically determined through fuzzy logic algorithm.
[0028] Furthermore, the process completion status includes at least: the completion status of the vacuuming process at the material feeding station, the completion status of the foaming material injection at the material injection station, and the remaining molding time calculated from the completion of material injection.
[0029] Furthermore, the central controller is configured to execute the following dynamic scheduling rules: If the digital twin models of the forming molds exceeding the set proportion are all displayed as "waiting for circulation", then control the circular conveyor 8 to shorten the dwell time in the current cycle; If the digital twin model of any molding die located at a critical station shows that its current process has not met the completion conditions, the circular conveyor 8 is controlled to extend the dwell time at the current station until the mold process is completed or the maximum waiting time limit is reached.
[0030] Furthermore, the central controller is configured such that when the digital twin model of a molding die receives a fault alarm signal from its control system, the die is marked as an abnormal die; in subsequent scheduling, the circular conveyor 8 is controlled to make the abnormal die skip the injection station and directly transfer to the designated maintenance station or material picking station.
[0031] Specifically, the digital twin model of each mold is a data structure that contains at least the following real-time fields: mold ID, current position, current process status (e.g., "empty", "filling complete", "curing", "waiting"), current process start time, and the estimated remaining time of the current process calculated based on the process formula (e.g., remaining curing time = standard curing time - cured time).
[0032] The input to the fuzzy logic algorithm is the global state, such as the proportion of "waiting for transfer" molds, the number of molds with "critical workstations not completed", and the severity of timeout for a single mold process; its output is a decision instruction, such as "rotate immediately", "rotate after X seconds", and "mark mold M as jump".
[0033] The specific rules include: Shorten the interval rule: When the system detects that more than 70% (this percentage is adjustable) of the mold twins are in the "waiting to flow" state (i.e. all processes of the current station have been completed), it is determined that "the system has a high idle degree". Even if the preset cycle time has not been reached, the production line is immediately ordered to rotate and enter the next cycle. Extended dwell time rule: When any mold located at a critical station such as injection has a twin display status that is not "complete" (e.g., still in vacuuming or injection), and its expected completion time is later than the preset station dwell time deadline, it is judged as "critical process delay". The central controller will order the production line drive to remain stationary until the mold process is completed or a maximum tolerable delay (e.g., 30 seconds) is reached, in order to prioritize the integrity of the process.
[0034] Abnormal jump rule: When the control system of a mold reports a fault, its twin is marked as "abnormal"; in subsequent scheduling, the central controller will modify the process flow of the mold, and when the production line is rotating, it will control it to skip the injection station that requires normal products and directly transport it to the maintenance station or material picking station for cleaning, so as to avoid contaminating the injection equipment or generating waste products.
[0035] Furthermore, the feeding station and / or unloading station are equipped with vision assistance units; The vision assistance unit includes an image acquisition device and a prompting device. The image acquisition device is configured to acquire images of the operating area, and the central controller or a local processing unit is configured to analyze the images to determine whether the fabric is placed correctly during feeding or whether the workpiece has been completely removed during retrieval. The prompting device provides guidance or warning information to the operator.
[0036] Specifically, industrial cameras or vision sensors are installed above the material feeding and material picking stations as image acquisition devices. At the material feeding station, the vision assistance unit captures an image of the mold with the fabric already placed on it. The image processing algorithm identifies whether the edge of the fabric exceeds the pressing area of the pressing frame 31 and whether there are obvious wrinkles. If a defect is detected, an alarm is triggered by the indicator light (red) or voice prompt (prompt device) at that station to guide the worker to make adjustments. At the material picking station, the vision unit captures an image of the mold cavity after the mold is opened to determine whether the finished product has been completely demolded and taken away. If any residue is detected, an alarm is issued to prevent damage to the mold during mold closing. This step digitizes and standardizes the key points of manual operation, significantly reducing the human error rate.
[0037] Through the above steps, this invention introduces state-sensing control based on vacuum degree change rate and adaptive filling compensation combined with ambient temperature, enabling the equipment to adapt to different process states. This fundamentally ensures the consistency of the bonding quality of the saddle fabric preform and the uniformity of the foam filling, significantly reducing the product defect rate caused by the solidification of process parameters. Furthermore, through flexible dynamic scheduling, this invention ensures that the production line's rhythm is no longer a fixed bottleneck, but is flexibly adjusted according to the actual production pace. This maximizes equipment utilization and overall production efficiency while ensuring sufficient processing time for each product.
[0038] Example 2 Optionally, this embodiment proposes an intelligent molding die with adaptive vacuum control function.
[0039] The molding die includes a die base 1, a saddle mold frame 2, a die top plate 3, and a locking mechanism 4. The saddle mold frame 2 is shaped like a bicycle saddle and is fixedly embedded in the inner cavity of the die base 1 by interference fit or bolts. A gap is left between the bottom of the saddle mold frame 2 and the inner bottom surface of the die base 1 to form a sealed cavity 5. Microholes 21 with a diameter of micrometers are evenly distributed on the saddle mold frame 2 to connect the inner surface of the die cavity and the cavity 5. An air pipe 6 connector is fixed on the outside of the die base 1 to connect the air pipe 6.
[0040] The mold top plate 3 is connected to one side edge of the mold base 1 via a hinge and can be rotated around the hinge axis. The mold top plate 3 itself is composed of a pressing frame 31 and a pressing plate 32 installed coaxially, which can be rotated synchronously or independently relative to the mold base 1. The locking mechanism 4 is a manual quick clamp, installed on the other side of the mold base 1 opposite to the hinge, and is used to lock the pressing plate 32 after the mold is closed.
[0041] This embodiment integrates a control system, which includes a programmable logic controller (PLC) or embedded microcontroller as the core processing unit. This processing unit is electrically connected to a vacuum pump (air pump 7) configured independently for the mold via its digital input / output (I / O) module or analog input module. The vacuum pump is connected to the air pipe 6 via a pipeline. The processing unit can send start / stop signals to control the vacuum pump and can read the operating current signal of the vacuum pump's drive motor in real time. .
[0042] The specific implementation steps of this embodiment are as follows: Initialization and fabric placement: The operator lays the cut saddle leather fabric flat on the inner surface of the open saddle mold 2, and tidies the edges of the fabric to the predetermined pressing area of the pressing frame 31. Then, the operator manually flips the pressing frame 31 to initially press the edges of the fabric.
[0043] Initiating adaptive vacuuming: The operator initiates the vacuuming process of the mold through the human-machine interface (HMI) or buttons; the control system sends a start command to the vacuum pump to begin evacuating the cavity 5.
[0044] Current signal monitoring and vacuum level calculation: The control system continuously reads the operating current of the vacuum pump motor at a fixed sampling period (e.g., 100ms). Through preliminary calibration experiments, the steady-state operating current and outlet vacuum level of this model of vacuum pump under standard load have been established. Correspondence function (unit: kPa, relative vacuum) The function can be a lookup table or a fitted linear / nonlinear equation; therefore, the system can calculate the corresponding vacuum level estimate in real time. .
[0045] Change rate calculation and state judgment: The system records the estimated vacuum level in its internal memory. Over time It calculates the real-time rate of change of the vacuum level (i.e., the instantaneous slope of the curve). ; It can be approximated by calculating the difference between adjacent sampling points, for example: in, For the nth sampling time, This is an estimated value of the vacuum level at that moment.
[0046] In the initial stage of vacuuming, the space between cavity 5 and the back of the fabric is large, allowing gas to be rapidly extracted. The value is negative and has a large absolute value (steep slope); as the vacuum level increases, the fabric gradually adheres to the inner wall of the mold frame under the action of the air pressure difference, and the residual gas is mainly extracted through the gaps between the fabric fibers and the micropores 21, increasing the exhaust resistance. The absolute value decreases rapidly.
[0047] Fitting completion judgment and action execution: The system presets a negative rate of change threshold. (e.g., -0.5 kPa / s); calculated over several consecutive sampling periods Greater than (i.e., the absolute value is less than) When the system determines that the change in vacuum level has become gradual and the leather fabric of the saddle has basically completely adhered to the inner wall of the saddle mold frame 2, the control system automatically sends a stop command to the vacuum pump or switches to a low-power pressure holding mode to prevent excessive suction.
[0048] Subsequent process: After the fabric is shaped, the operator uses an external injection gun to inject a predetermined amount of foaming material into the mold cavity; then manually closes the pressing plate 32 and locks it with the locking mechanism 4, waiting for the foaming material to solidify and form.
[0049] The beneficial effect of this embodiment is that it transforms the vacuuming process from open-loop control that relies on a fixed time to closed-loop control based on feedback of physical state (vacuum degree change rate); no matter how the breathability of the leather fabric changes, the system can automatically find the optimal point to stop vacuuming, ensuring the consistency of the fit quality and avoiding wrinkles caused by under-vacuuming or energy waste and potential fabric damage caused by over-vacuuming.
[0050] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.
Claims
1. A molding die for saddle production, comprising a die base (1), a saddle die frame (2), a die top plate (3), and a locking mechanism (4), wherein the saddle die frame (2) is shaped like a bicycle saddle and is embedded inside the die base (1), a cavity (5) is formed between the bottom of the saddle die frame (2) and the inner bottom surface of the die base (1), a microhole (21) communicating with the cavity (5) is provided on the saddle die frame (2), an air pipe (6) communicating with the cavity (5) is provided on the outer side of the die base (1), the edge of the die top plate (3) is hinged to the edge of the die base (1), and the die top plate (3) includes a pressing frame (31) and a pressing plate (32) that can rotate coaxially; characterized in that: Also includes: The control system is configured to communicate with the air pump (7) connected to the air pipe (6); The control system is further configured to: when the air pump (7) is used to evacuate the cavity (5), calculate the vacuum change rate based on the real-time change data of the vacuum degree in the air pipe (6); when the vacuum change rate is detected to change from the initial rapid decrease state to a flat state below the preset threshold, it is determined that the saddle leather fabric has been attached to the inner wall of the saddle mold frame (2), and the air pump (7) is controlled to stop or switch to the pressure holding mode.
2. The molding die based on saddle production according to claim 1, characterized in that: The control system is configured to: indirectly estimate the vacuum level in the air pipe (6) by monitoring the operating current of the air pump (7), and calculate the vacuum level change rate based on the curve of vacuum level change over time.
3. A molding die based on saddle production according to claim 1 or 2, characterized in that: The control system is further configured to: record the time taken for the vacuum change rate to decrease from the initial value to the preset threshold, and compare the time with the preset standard time range; if the time exceeds the standard time range, it is determined that there is an abnormal fabric placement or air leakage fault, and an alarm signal is triggered.
4. A molding die based on saddle production according to claim 1, characterized in that: The control system is also communicatively connected to an injection device that injects foaming material into the saddle mold frame (2); The control system is configured to: collect ambient temperature data and dynamically adjust the injection parameters of the injection equipment according to a pre-stored injection volume-temperature compensation relationship model, so as to compensate for the difference in the flowability of the foaming material caused by changes in ambient temperature.
5. A molding die based on saddle production according to claim 4, characterized in that: The control system is configured to continuously record the actual ambient temperature, adjusted injection parameters, and corresponding mold identifier for each production process; and to iteratively optimize the parameters in the injection volume-temperature compensation relationship model based on the subsequently obtained molding quality feedback information of the corresponding product in the mold.
6. A molding production line based on saddle production, characterized in that: include: Multiple molding dies as described in any one of claims 1-5; An annular conveyor (8) wherein the plurality of forming molds are arranged circumferentially along its annular conveyor frame; Multiple workstations are set along the conveying path of the circular conveyor (8), including at least a material feeding workstation, a material injection workstation, and a material picking workstation; The central controller is communicatively connected to the drive unit of the circular conveyor (8) and the control system of each forming mold; The central controller is configured to: establish and maintain a digital twin model for each molding die, and the digital twin model synchronizes the process completion status of the corresponding die at each workstation in real time; based on the digital twin model status of all molding dies, the rotation timing and dwell time of the annular conveyor (8) are dynamically determined by fuzzy logic algorithm.
7. A molding production line based on saddle production according to claim 6, characterized in that: The process completion status includes at least: the completion status of the vacuuming process at the material feeding station, the completion status of the foaming material injection at the material injection station, and the remaining molding time calculated after the material injection is completed.
8. A molding production line based on saddle production according to claim 7, characterized in that: The central controller is configured to execute the following dynamic scheduling rules: If the digital twin models of the forming molds exceeding the set ratio are all displayed as "waiting for circulation", then control the annular conveyor (8) to shorten the dwell time in the current cycle; If the digital twin model of any molding die located at a critical station shows that its current process has not met the completion conditions, the circular conveyor (8) is controlled to extend the dwell time at the current station until the mold process is completed or the maximum waiting time limit is reached.
9. A molding production line based on saddle production according to claim 6, characterized in that: The central controller is configured to: when a digital twin model of a molding die receives a fault alarm signal from its control system, mark the die as an abnormal die; in subsequent scheduling, control the ring conveyor (8) to make the abnormal die skip the injection station and directly transfer to the designated maintenance station or material picking station.
10. A saddle-based molding production line according to claim 6, characterized in that: The feeding station and / or unloading station are equipped with a visual assistance unit; The visual assistance unit includes an image acquisition device and a prompting device. The image acquisition device is configured to acquire images of the operation area. The central controller or a local processing unit is configured to analyze the images to determine whether the fabric is placed correctly during feeding or whether the workpiece has been completely removed during retrieval. The prompting device provides guidance or warning information to the operator.