A paper cup production quantity data tracing system

Abstract

The application relates to the technical field of paper cup production, in particular to a paper cup generation quantity data tracing system, which comprises a sensing and collecting module used for synchronously acquiring a speed parameter of a conveying belt and an independent shielding time length signal; a feature fusion module used for processing the independent shielding time length signal to generate a time length fusion feature and generating a length fusion feature based on the speed parameter and the time length fusion feature; and a cooperative judgment module configured to execute double-feature cooperative judgment logic, that is, comparing the time length fusion feature with a preset cup connection time length judgment threshold value, simultaneously comparing the length fusion feature with a preset cup connection length judgment threshold value, and outputting a cup connection judgment instruction to trigger counting of two paper cups only when the comparison results of the two satisfy respective cup connection judgment conditions. Through double-sensor cooperative measurement and real-time speed calibration, the application can realize accurate recognition and counting of cup connection, so as to solve the problem of missed counting caused by misjudgment in high-speed production.

Description

Technical Field

[0001] This application relates to the technical field of paper cup production, and in particular to a paper cup production quantity traceability system. Background Technology

[0002] As a widely used disposable container, paper cups rely heavily on high-speed automated production lines for large-scale production. In such a continuous, high-speed operating environment, accurate and real-time counting and data traceability of the produced paper cups are key to controlling production efficiency, material consumption, and product quality.

[0003] Currently, mainstream automatic counting solutions in the industry generally employ photoelectric sensing technology, triggering counting pulses by detecting the blocking and restoration of a light beam as a paper cup passes by. To further improve reliability, some improved solutions use a dual photoelectric sensor configuration spaced apart along the transmission direction. This aims to distinguish between normal single cups and "connected cups" formed by adhesion by analyzing the temporal relationship between the two sensor signal sequences (such as triggering order, signal overlap, or interval time), thereby reducing the risk of misjudgment.

[0004] However, in actual high-speed, complex production lines, the aforementioned existing technical solutions still face profound challenges that lead to counting errors, making it difficult to achieve highly accurate and stable traceability. First, the lighting conditions in the production line environment are not constant. Interference signals generated by the reflection of printed patterns or materials on the paper cup surface can conflict with the fixed detection threshold preset by traditional photoelectric sensors. This may cause the effective occlusion signal output by the sensor to be clipped or shortened, making the occlusion duration collected by the system unable to accurately reflect the actual physical length of the paper cup. This is especially true for longer consecutive cups, where the characteristic duration is easily distorted by interference. Second, and more critically, existing dual-sensor-based solutions have limitations in their decision logic when handling consecutive cups. These solutions typically rely on judging the combined relationship of two sensor signal events (such as rising and falling edges), or attempting to use the sensor spacing and trigger time difference to estimate the object's speed or roughly estimate its passage state. However, in high-speed scenarios where slight vibrations or conveyor slippage may occur, simply relying on signal event logic or failing to deeply integrate and calculate with real-time, accurate speed information makes it difficult to accurately restore the crucial physical characteristic of the object's true axial length. Therefore, existing systems essentially still rely primarily on counting occlusion events, or supplemented by easily disturbed single temporal features for discrimination, lacking a mechanism for collaborative judgment based on two independent yet mutually verifiable physical dimensions: occlusion duration and axial length calculated based on precise speed. This leads to the system being easily disturbed by its single or insufficiently precise features when dealing with consecutive cups, especially under complex conditions of ambient light interference and high-speed operation, making it impossible to clearly distinguish from a single cup and thus causing missed counts. Although the probability of a single missed count is low, in large-scale, continuous production, its cumulative error directly affects the accuracy and reliability of production data traceability, becoming a core bottleneck restricting breakthroughs in counting accuracy. Summary of the Invention

[0005] In order to achieve accurate identification and counting of consecutive cups through dual-sensor collaborative measurement and real-time speed calibration, and to solve the problem of missed counting caused by misjudgment in high-speed production, this application provides a paper cup production quantity data traceability system.

[0006] This application provides a paper cup production quantity data traceability system, which adopts the following technical solution: A paper cup production quantity data traceability system, comprising:

[0007] The sensor acquisition module is used to synchronously acquire the speed parameters of the conveyor belt and the independent occlusion duration signal generated when an object passes through at least two detection points set at intervals along the transmission direction.

[0008] The feature fusion module, connected to the sensing acquisition module, is used to process the independent occlusion duration signal to generate a duration fusion feature characterizing the time it takes for an object to pass through, and to generate a length fusion feature characterizing the physical size of the object based on the operational relationship between the velocity parameter and the duration fusion feature.

[0009] The collaborative decision module, connected to the feature fusion module, is configured to execute dual-feature collaborative decision logic: comparing the duration fusion feature with a preset consecutive cup duration judgment threshold, and simultaneously comparing the length fusion feature with a preset consecutive cup length judgment threshold, and outputting a consecutive cup decision instruction to trigger the counting of the two paper cups only when both comparison results meet their respective consecutive cup judgment conditions.

[0010] Optionally, a feedback calibration module is also included, which is connected to the collaborative decision module and configured to adaptively adjust the consecutive cup duration determination threshold and the consecutive cup length determination threshold based on the historical missed count rate and historical miscount rate statistically collected by the system.

[0011] Optionally, the collaborative decision module is further configured to execute single-cup collaborative decision logic: comparing the duration fusion feature with a preset single-cup duration threshold range, and simultaneously comparing the length fusion feature with a preset single-cup length threshold range; and outputting a single-cup decision instruction to trigger counting of a paper cup only when both comparison results satisfy their respective single-cup determination conditions; the single-cup collaborative decision logic and the dual-feature collaborative decision logic together constitute a complete paper cup status decision system.

[0012] Optionally, the feedback calibration module is further configured to: adaptively adjust the single-cup duration threshold range and the single-cup length threshold range based on the historical missed count rate and the historical miscount rate, so as to coordinate with the threshold adjustment of the dual-feature collaborative decision logic.

[0013] Optionally, an exception handling module is also included. The exception handling module is connected to the collaborative decision module and is configured to trigger the execution of a preset exception response operation when the duration fusion feature and the length fusion feature cannot simultaneously satisfy the consecutive cup determination condition of the dual-feature collaborative decision logic, and also cannot simultaneously satisfy the single cup determination condition of the single cup collaborative decision logic.

[0014] Optionally, the sensing acquisition module further includes an ambient light adaptive unit, which is configured to dynamically adjust the signal threshold on which the at least two detection points generate the independent occlusion duration signal based on the real-time monitored ambient light intensity, so as to compensate for the impact of ambient light changes on signal integrity.

[0015] Optionally, a speed calibration module is also included. The speed calibration module is connected to the sensing acquisition module and the feature fusion module and is configured to: calculate a speed verification value using a fixed distance between the at least two detection points and the time difference between the triggering of the at least two detection points by the same object; compare the speed verification value with the speed parameter acquired by the sensing acquisition module in real time; and trigger a calibration process for the speed parameter when the deviation between the two exceeds a preset allowable threshold.

[0016] Optionally, the feature fusion module is configured to: when performing the operation of generating the length fusion feature, first rely on the real-time comparison result of the speed calibration module; only when the speed parameter is confirmed to meet the preset verification conditions, perform the operation of generating the length fusion feature based on the speed parameter and the duration fusion feature.

[0017] Optionally, the spacing between the at least two detection points along the transmission direction is configured to be associated with the standard axial length of a single paper cup.

[0018] Optionally, the feature fusion module is configured to process the independent occlusion duration signals from the at least two detection points, the processing including calculating the average value of the at least two independent occlusion duration signals to generate the interference-resistant duration fusion feature.

[0019] In summary, this application includes the following beneficial technical effects:

[0020] By fusing independent occlusion duration signals from dual detection points to generate anti-interference duration fusion features, and combining them with real-time calibrated conveyor belt speed parameters to calculate accurate length fusion features, the system constructs a dual-feature system that describes objects from two independent dimensions: time and physical size. The collaborative decision module performs collaborative decision-making based on these dual features, meaning that both the duration and length thresholds for consecutive cups must be met simultaneously to identify them as consecutive cups and count them. This dual verification mechanism fundamentally overcomes the shortcomings of traditional single-sensor or single-time feature decision schemes, which are susceptible to signal interference and misjudgment. It achieves accurate identification of consecutive cup status during high-speed operation and directly solves the core technical problem of paper cup undercounting caused by misjudgment.

[0021] The system dynamically adjusts the detection threshold through an ambient light adaptive unit to compensate for the impact of illumination changes on signal integrity. At the same time, it uses a feedback calibration module to adaptively adjust the decision thresholds for consecutive cups and single cups based on historical missed count and false count data. This enables the system to not only resist the instantaneous interference of illumination fluctuations in the production site, but also to continuously optimize the decision parameters during long-term operation to adapt to subtle changes in the production line, thereby significantly improving the system's environmental adaptability and long-term counting stability under different operating conditions.

[0022] By establishing a speed calibration module, the conveyor belt speed is verified and calibrated in real time using the fixed spacing and trigger time difference between the two detection points, ensuring the high accuracy of the speed parameter used to calculate the length of the object. Combined with an anomaly handling module, abnormal states that cannot be classified as single cups or consecutive cups are captured and responded to, the counting is paused and an alarm is triggered. This series of designs together constitute a closed-loop system with self-verification, fault tolerance and anomaly handling capabilities, ensuring the overall reliability and credibility of the final production quantity traceability data from the data source and process control. Attached Figure Description

[0023] Figure 1 This is a flowchart of the dual-feature collaborative decision-making process;

[0024] Figure 2 This is a flowchart of dynamic calibration and adaptive optimization. Detailed Implementation

[0025] The following combination Figures 1-2 This application will be described in further detail.

[0026] This application discloses a paper cup production quantity data traceability system. For example... Figure 1 As shown, a paper cup production quantity data traceability system aims to achieve accurate identification and counting of consecutive cups through technologies such as dual-sensor collaborative measurement and real-time speed calibration, thereby solving the problem of missed counting caused by misjudgment in high-speed production.

[0027] Before system deployment, based on the actual working conditions and industry standards of the high-speed paper cup production line, the following core parameters were preset: the rated operating speed range of the conveyor belt is 0.8m / s-1.2m / s, and the default initial speed calibration value is set to 1m / s; the standard axial length of a single paper cup is L=0.05m, corresponding to the standard blocking time. =L / v=0.05s (i.e., 50ms); the theoretical axial length of the cup is 2L=0.1m, corresponding to a theoretical shading duration of 2 =100ms; the interval between the two detection points along the transmission direction is set to 0.05m, consistent with the standard axial length of a single paper cup; the preset threshold for determining the continuous cup duration is 90ms (1.8). The threshold for determining the length of the cup is 0.09m (1.8L); the preset threshold range for single cup duration is 40ms-60ms, and the threshold range for single cup length is 0.04m-0.06m; the allowable deviation threshold for speed verification is set to ±1%, and the ambient light intensity monitoring range is 500Lux-1000Lux.

[0028] This system includes a sensor acquisition module, a feature fusion module, a collaborative decision module, a feedback calibration module, an anomaly handling module, and a speed calibration module. The following steps will be described in detail:

[0029] S1: Deployment of sensor acquisition module and acquisition of basic data

[0030] The sensing module simultaneously acquires the speed parameters of the conveyor belt and the independent occlusion duration signal of the object passing through the dual detection points. At the same time, it ensures signal quality through adaptive adjustment of ambient light. This design effectively avoids the shortcomings of traditional single sensor acquisition, which is susceptible to environmental interference, and improves the reliability of the raw data.

[0031] S11: Installation of detection points and sensors

[0032] Two photoelectric sensors are arranged parallel to each other along the conveyor belt's transmission direction, forming a dual detection point. The interval between the detection points is set to 0.05m, a value that matches the standard axial length of a single paper cup in the industry. Multiple tests on the production line have verified that this spacing significantly differentiates the occlusion signals generated when a single cup passes through versus when cups are connected in a row, providing a foundation for subsequent signal differentiation. A reflective sensor is installed on the same side as the first detection point, with its detection end facing the paper cup surface, to capture changes in ambient light intensity in real time. A speed sensor is installed at the conveyor belt drive end, with an accuracy set at ±0.001m / s. This accuracy parameter was determined through simulation experiments and meets the precise speed acquisition requirements of a high-speed production line. All sensor detection directions are perpendicular to the paper cup's axial direction to avoid interference from radial reflections from the paper cup on the detection signal.

[0033] S12: Ambient light adaptive threshold adjustment

[0034] The reflective sensor collects ambient light intensity at a frequency of 10Hz. This frequency has been optimized through actual operating condition testing, ensuring timely response to changes in illumination without increasing system redundancy. The collected light intensity signal is transmitted in real time to the ambient light adaptive unit. This unit has a built-in offline test-based mapping relationship between reflective intensity and signal threshold. This mapping relationship is established based on sensor signal integrity test data under different illumination conditions, providing reliable experimental evidence. According to the real-time illumination intensity, the ambient light adaptive unit dynamically adjusts the occlusion detection thresholds of the two photoelectric sensors: when the ambient light intensity is 500 Lux, the threshold is set to 3V; when the illumination rises to 1000 Lux, the threshold is adjusted to 4V; when the illumination is in the range of 500 Lux to 1000 Lux, the threshold is dynamically adapted by linear interpolation. The monitoring range of 500 Lux to 1000 Lux covers the normal illumination environment of most paper cup production workshops, and the corresponding threshold parameters can effectively compensate for the impact of illumination changes on the signal, avoiding peak clipping or shortening of the signal due to occlusion. When the signal received by the photoelectric sensor is less than or equal to the adjusted threshold, it is determined to be in an occluded state; when it is greater than the threshold, it is determined to be in an unoccluded state.

[0035] S13: Synchronous acquisition of velocity parameters and occlusion duration signals

[0036] The speed sensor collects the conveyor belt speed parameter in real time at a frequency of 100Hz. This frequency is determined with reference to industry standards for speed monitoring on high-speed production lines, ensuring the real-time nature of the speed data and meeting the requirements of subsequent calibration and feature calculation. The speed data is synchronously transmitted to the feature fusion module and the speed calibration module. When a paper cup or a continuous stream of cups passes through the dual detection points, each photoelectric sensor records the start and end times of the obstruction: the first detection point calculates the difference between the end and start times of the obstruction to obtain the duration of the first independent obstruction. The second detection point was used to calculate the duration of the second independent occlusion. Two independent occlusion duration signals are transmitted synchronously to the feature fusion module, providing high-quality raw data for the subsequent generation of fused features.

[0037] S2: Speed ​​calibration module speed verification and calibration

[0038] like Figure 2 As shown, the speed calibration module connects the sensing acquisition module and the feature fusion module. It calculates a speed verification value using the fixed spacing between two detection points and the time difference between triggering the two detection points on the same object. This verification value is then compared in real-time with the speed parameters acquired by the sensors. Calibration is triggered when the deviation exceeds a preset threshold. This design based on dual-detection-point linkage verification effectively overcomes the shortcomings of existing technologies where single speed measurements are prone to errors, improving the reliability of speed data and thus supporting the accuracy of subsequent feature extraction.

[0039] S21: Speed ​​Verification Value Calculation

[0040] The velocity calibration module receives occlusion event time data from two detection points transmitted by the sensor acquisition module. When the same object passes through the two detection points, the occlusion state will be triggered sequentially. The velocity calibration module extracts the occlusion start time of the first detection point. The moment of occlusion at the second detection point The time interval between the two detection points was calculated. ,Right now Combining the preset fixed spacing D (0.05m) between the two detection points in step S1, and based on normal operating conditions where the conveyor belt runs smoothly and there is no serious relative slippage between the paper cup and the conveyor belt, the object passes through two adjacent detection points in a short time interval. The interior can be approximated by the reasonable assumption that it remains relatively stationary with respect to the conveyor belt and moves at a uniform linear velocity. The speed verification value is calculated based on the principles of kinematics. The calculation formula is: The fixed spacing unit is m, the time difference unit is s, and the calculated velocity verification value is in m / s, which is consistent with the unit of the velocity parameter acquired by the sensor, ensuring dimensional consistency.

[0041] S22: Velocity parameter comparison and calibration trigger

[0042] The speed calibration module compares the calculated speed verification value with the speed parameter acquired by the sensor acquisition module in real time, calculating the deviation rate between the two. The deviation rate is the ratio of the absolute value of the difference between the speed verification value and the speed parameter to the absolute value of the speed parameter, expressed as a percentage. The system's preset allowable deviation threshold for speed verification is 1%, which was optimized through multiple production line simulation experiments to balance speed measurement accuracy and system response efficiency. When the deviation rate is less than or equal to 1%, the speed calibration module determines that the speed parameter meets the verification conditions, marks it as valid, and transmits it to the feature fusion module; when the deviation rate is greater than 1%, the speed calibration module triggers the calibration process. The calibration process re-acquires the conveyor belt speed parameter by calibrating the speed parameter until the deviation rate meets the allowable threshold requirement, ensuring the measurement accuracy of the conveyor belt speed parameter.

[0043] S3: Feature Fusion Module - Feature Generation

[0044] like Figure 1 As shown, the feature fusion module connects the sensing acquisition module and the velocity calibration module. It performs anti-interference processing on the independent occlusion duration signal to generate duration fusion features, and calculates length fusion features based on the calibrated velocity parameters and duration fusion features. The two fused features characterize the object's properties from the dimensions of time and physical size, respectively, laying the foundation for dual-feature collaborative decision-making and effectively improving the discriminativeness and reliability of the feature data.

[0045] S31: Generation of Temporal Fusion Features

[0046] The feature fusion module receives two independent occlusion duration signals from the sensor acquisition module. To compensate for signal distortion caused by occasional fluctuations (such as random electrical noise or transient foreign object interference) in a single sensor, the feature fusion module performs anti-interference processing on the two independent occlusion duration signals. This processing involves calculating the average of the two independent occlusion duration signals to suppress random interference and generate stable duration fusion features. This processing method has been verified through multiple production line simulation experiments, demonstrating that it significantly reduces the impact of random interference from a single sensor and improves the stability of feature data. The independent occlusion duration of the first detection point is... The duration of independent occlusion at the second detection point is Duration fusion features The calculation method is as follows: The duration fusion feature is measured in milliseconds (ms), which accurately characterizes the time characteristics of an object passing through a detection point.

[0047] S32: Length Fusion Feature Generation

[0048] The feature fusion module first obtains the real-time comparison results from the speed calibration module. Only when the speed parameter is confirmed to meet the preset verification conditions does it perform the length fusion feature generation calculation based on the speed parameter and the duration fusion feature. This design ensures the accuracy of the speed parameter on which the length fusion feature calculation depends, avoiding distortion of the length feature caused by speed deviation. Under normal production conditions with appropriate conveyor belt tension and stable paper cup placement, the paper cup and conveyor belt can be considered to move synchronously. Therefore, according to the kinematics principle, its axial projected length is equal to the product of the speed and the time taken. The calibrated conveyor belt speed parameter is v (unit: m / s), and the duration fusion feature... (Unit: ms) needs to be converted to seconds. The length fusion feature L is calculated as follows: The calculated length fusion feature is in meters (m), accurately reflecting the physical dimensions of the object. If the velocity parameter fails verification, the feature fusion module pauses length fusion feature generation, waiting for the velocity calibration module to complete calibration and output a velocity parameter that meets the verification conditions before resuming the length fusion feature generation operation.

[0049] S4: Paper Cup Status Judgment in the Collaborative Judgment Module

[0050] like Figure 1 As shown, the collaborative decision module connects to the feature fusion module, executing the dual-feature collaborative decision logic for both connected and single cups, thus constructing a complete paper cup state decision system. Through mutual verification of the time-dimensional duration fusion feature and the spatial-dimensional length fusion feature, accurate differentiation between single and connected cups is achieved, providing solid support for subsequent counting operations.

[0051] S41: Cooperative Decision Based on Dual Features of Consecutive Cups

[0052] The collaborative decision-making module calls the preset thresholds for determining the duration and length of consecutive cups. The duration threshold is set to 90ms, and the length threshold is set to 0.09m. These thresholds are based on the following considerations: the standard axial length of a single paper cup is 0.05m, corresponding to a standard occlusion duration of 50ms; the theoretical axial length of consecutive cups is 0.1m, and the theoretical occlusion duration is 100ms. To ensure reliable identification and accommodate slight dimensional deviations in production, while avoiding overlap with the single-cup characteristic range (duration 40-60ms, length 0.04-0.06m), after simulation optimization, a value slightly lower than the theoretical value but much higher than the upper limit of a single cup is selected as the threshold (approximately 0.9 times the theoretical value and 1.5 times the upper limit of a single cup). The collaborative decision-making module compares the duration fusion feature with the consecutive cup duration threshold and the length fusion feature with the consecutive cup length threshold. The consecutive cup determination condition is met only when the duration fusion feature is greater than or equal to 90ms and the length fusion feature is greater than or equal to 0.09m. At this point, the collaborative decision module outputs a "cup-matching" decision command, triggering the counting module to count the two paper cups. The decision logic, which satisfies both features simultaneously, significantly reduces the probability of misjudgment caused by interference from a single feature through the mutual constraint of two independent physical dimensions.

[0053] S42: Single-cup dual-feature collaborative decision

[0054] The collaborative decision module invokes preset threshold ranges for single-cup duration and length. The single-cup duration threshold range is 40ms to 60ms, and the single-cup length threshold range is 0.04m to 0.06m. These threshold ranges fully account for slight dimensional deviations in paper cups during production and have been verified by extensive experimental data to accurately cover the characteristic fluctuation range of normal single cups. The collaborative decision module compares the duration fusion feature with the single-cup duration threshold range and simultaneously compares the length fusion feature with the single-cup length threshold range. The single-cup judgment condition is met only when the duration fusion feature is between 40ms and 60ms and the length fusion feature is between 0.04m and 0.06m. At this point, the collaborative decision module outputs a single-cup judgment command, triggering the counting module to count one paper cup. The single-cup judgment logic and the consecutive-cup judgment logic complement each other, ensuring accurate identification of normal single cups during production.

[0055] S5: Exception handling module's exception response

[0056] like Figure 1As shown, the anomaly handling module is connected to the collaborative decision module. It identifies the abnormal state output by the collaborative decision module and executes preset response operations. After the collaborative decision module completes the dual-feature collaborative decision for single cups and consecutive cups, if the duration fusion feature and length fusion feature cannot simultaneously satisfy the consecutive cup judgment condition or the single cup judgment condition, the anomaly handling module determines that the current situation is abnormal. This anomaly identification method based on dual-feature decision results can accurately capture problems such as non-standard objects or signal interference in production, providing a clear basis for subsequent fault diagnosis.

[0057] S51: Abnormal State Determination

[0058] The anomaly handling module receives the judgment results from the collaborative judgment module in real time, along with the corresponding duration fusion feature and length fusion feature data. The anomaly handling module verifies the received data to confirm whether the duration fusion feature and length fusion feature exceed the judgment range for a single cup or consecutive cups. For example, if the duration fusion feature is 30ms and the length fusion feature is 0.03m, both are below the lower limit of the single cup threshold range; or if the duration fusion feature is 70ms and the length fusion feature is 0.08m, neither the single cup judgment condition nor the consecutive cup judgment condition is met. In these cases, the anomaly handling module determines the current state to be abnormal.

[0059] S52: Execution of preset exception response operations

[0060] Upon determining an abnormal state, the anomaly handling module immediately triggers preset anomaly response operations. First, it activates the audible and visual alarm device at a frequency of 2Hz, a frequency that quickly attracts staff attention without excessively interfering with the production environment. Second, the anomaly handling module records relevant anomaly data, including the time of the anomaly, the current conveyor belt speed parameter, and the specific values ​​of the time-fusion and length-fusion characteristics. This data provides crucial information for subsequent troubleshooting. Finally, the anomaly handling module sends a control signal to the counting module, pausing its counting operation until staff have troubleshooted and reset the system. Only then does the counting module resume normal counting, effectively preventing abnormal data from entering the counting statistics and ensuring the accuracy of production data traceability.

[0061] S6: Adaptive threshold adjustment of the feedback calibration module

[0062] like Figure 2 As shown, the feedback calibration module is connected to the collaborative decision module. It statistically analyzes the historical omission rate and miscount rate of the system operation, and adjusts the decision thresholds for consecutive cups and single cups respectively based on the statistical results. By dynamically optimizing the decision logic of the collaborative decision module through the thresholds, the entire decision system can adapt to subtle changes in the production line and maintain a high recognition accuracy.

[0063] S61: Historical omission and error rates statistics

[0064] The system uses a 24-hour statistical cycle to collect real-time production-related data. Theoretical output is calculated based on the production line's rated capacity and actual operating time, while actual counts are the cumulative values ​​recorded by the counting module. To simplify the statistical model, this embodiment defines the undercount as the difference between theoretical output and actual counts, and the miscount as the difference between actual counts and theoretical output. In practical applications, the system can combine records from the anomaly handling module to cross-validate and correct the above statistics to improve statistical accuracy. Based on this, the undercount rate and miscount rate are calculated: the undercount rate is the ratio of undercount to theoretical output multiplied by 100%, and the miscount rate is the ratio of miscount to theoretical output multiplied by 100%. The 24-hour statistical cycle, verified by actual production line testing, accurately reflects the system's stable operating status and provides reliable data support for subsequent threshold adjustments.

[0065] S62: Adjustment of consecutive cup judgment threshold

[0066] The feedback calibration module adaptively adjusts the thresholds for determining consecutive cup duration and consecutive cup length based on historical missed and false count rates. The system presets an allowable threshold of 0.01% for both missed and false count rates. This threshold, determined through multiple simulation experiments, balances counting accuracy with system adjustment stability. The adjustment strategy is as follows:

[0067] When the missed detection rate is greater than 0.01% and the false detection rate is less than 0.01%, it indicates that some cups are not effectively identified. The feedback calibration module will lower the threshold for judging the duration of cups by 5ms and the threshold for judging the length of cups by 0.005m.

[0068] When the miscounting rate is greater than 0.01% and the omission rate is less than 0.01%, it indicates that a single cup is misjudged as a continuous cup. The feedback calibration module will raise the continuous cup duration judgment threshold by 5ms and the continuous cup length judgment threshold by 0.005m.

[0069] If both the omission rate and the miscount rate exceed 0.01%, it indicates that there is complex interference in the current operating conditions or that the system parameters may be abnormal. The feedback calibration module will pause the automatic threshold adjustment and trigger an abnormal alarm, prompting staff to intervene and check the parameters. After manual confirmation or reset, the system will resume the threshold adaptive adjustment process based on the latest operating conditions.

[0070] The adjusted consecutive cup judgment threshold is synchronized to the collaborative judgment module in real time to ensure that the judgment logic is updated in a timely manner.

[0071] S63: Single-cup decision threshold adjustment

[0072] To coordinate the adjustment of consecutive cup judgment thresholds and ensure the consistency of the judgment system, the feedback calibration module simultaneously optimizes the single cup duration and single cup length threshold ranges based on historical omission and miscount rates. The adjustment strategy and the consecutive cup threshold adjustment logic work together to ensure the overall optimal judgment system.

[0073] When the missed count rate is high (>0.01%) but the miscount rate does not exceed the limit, it indicates that some normal single cups may not be accurately identified (or consecutive cups are missed, causing statistical deviation). The feedback calibration module will lower the upper and lower limits of the single cup duration threshold range by 5ms, and at the same time lower the single cup length threshold range by the same proportion.

[0074] When the miscounting rate is high (>0.01%) but the omission rate does not exceed the limit, it indicates that there are cases where non-standard objects are misjudged as single cups. The feedback calibration module will raise the upper and lower limits of the single cup duration threshold range by 5ms, and the single cup length threshold range will also be raised by the same proportion.

[0075] If both exceed the limits, the same strategy as S62 will be followed: pause automatic adjustment and trigger an alarm, waiting for manual intervention.

[0076] The adjusted single-cup decision threshold is synchronized to the collaborative decision module in real time to ensure that the single-cup and consecutive-cup decision thresholds match each other and maintain the optimal state of the entire decision system.

[0077] The implementation principle of the paper cup production quantity data traceability system in this application embodiment is as follows: This system deploys dual photoelectric sensors spaced apart along the transmission direction to synchronously collect the conveyor belt speed parameters and object occlusion duration signals, and uses an ambient light adaptive unit to dynamically adjust the detection threshold to resist light interference; the system first uses a speed calibration module to perform real-time verification and calibration of the speed parameters based on the fixed spacing between the dual detection points and the trigger time difference to ensure the accuracy of the speed data; then, the feature fusion module averages the occlusion duration signals from the dual sensors to generate anti-interference duration fusion features, and combines them with the calibrated speed... The system calculates the length fusion feature representing the physical size of the object. The collaborative decision module employs a dual-feature collaborative decision logic, simultaneously comparing the duration fusion feature with a preset duration threshold and the length fusion feature with a preset length threshold. Only when both conditions for determining whether a cup is connected or a single cup are met is the corresponding counting command output. This mutual verification across two independent dimensions—time and space—significantly improves the ability to distinguish between connected and single cups under high-speed and complex conditions. Furthermore, the system introduces a feedback calibration module, adaptively adjusting the decision threshold based on historical missed and false count rates, enabling the system to continuously adapt to changes in the production line. This collaborative measurement, real-time calibration, and dual-decision mechanism effectively solves the problems of missed and false detections of connected cups caused by ambient light interference, speed fluctuations, and limited features in traditional single-sensor solutions, achieving high accuracy and stability in quantity traceability during paper cup production.

[0078] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A paper cup production quantity traceability system, characterized in that, include: The sensor acquisition module is used to synchronously acquire the speed parameters of the conveyor belt and the independent occlusion duration signal generated when an object passes through at least two detection points set at intervals along the transmission direction. The feature fusion module, connected to the sensing acquisition module, is used to process the independent occlusion duration signal to generate a duration fusion feature characterizing the time it takes for an object to pass through, and to generate a length fusion feature characterizing the physical size of the object based on the operational relationship between the velocity parameter and the duration fusion feature. The collaborative decision module, connected to the feature fusion module, is configured to execute dual-feature collaborative decision logic: compare the duration fusion feature with a preset consecutive cup duration judgment threshold, and compare the length fusion feature with a preset consecutive cup length judgment threshold. Only when both comparison results meet their respective consecutive cup judgment conditions, a consecutive cup decision instruction is output to trigger the counting of the two paper cups. It also includes a feedback calibration module, which is connected to the collaborative decision module and is configured to: adaptively adjust the consecutive cup duration determination threshold and the consecutive cup length determination threshold based on the historical omission rate and historical miscount rate statistically collected by the system. The collaborative decision module is also configured to execute single-cup collaborative decision logic: compare the duration fusion feature with a preset single-cup duration threshold range, and compare the length fusion feature with a preset single-cup length threshold range; and only when both comparison results satisfy their respective single-cup determination conditions, output a single-cup decision instruction to trigger counting of a paper cup; the single-cup collaborative decision logic and the dual-feature collaborative decision logic together constitute a complete paper cup status decision system; The feedback calibration module is further configured to: adaptively adjust the single cup duration threshold range and the single cup length threshold range based on the historical missed count rate and the historical miscount rate, so as to coordinate with the threshold adjustment of the dual-feature collaborative decision logic.

2. The system according to claim 1, characterized in that, It also includes an exception handling module, which is connected to the collaborative decision module and is configured to: trigger the execution of a preset exception response operation when the duration fusion feature and the length fusion feature cannot simultaneously satisfy the consecutive cup determination condition of the dual feature collaborative decision logic, and also cannot simultaneously satisfy the single cup determination condition of the single cup collaborative decision logic.

3. The system according to claim 1, characterized in that, The sensing acquisition module also includes an ambient light adaptive unit, which is configured to dynamically adjust the signal threshold on which the at least two detection points generate the independent occlusion duration signal based on the real-time monitored ambient light intensity, so as to compensate for the impact of ambient light changes on signal integrity.

4. The system according to claim 1, characterized in that, It also includes a speed calibration module, which is connected to the sensing acquisition module and the feature fusion module, and is configured to: calculate a speed verification value using a fixed distance between the at least two detection points and the time difference between the triggering of the at least two detection points by the same object; compare the speed verification value with the speed parameter acquired by the sensing acquisition module in real time; and trigger a calibration process for the speed parameter when the deviation between the two exceeds a preset allowable threshold.

5. The system according to claim 4, characterized in that, The feature fusion module is configured to: when performing the operation of generating the length fusion feature, first rely on the real-time comparison result of the speed calibration module; only when the speed parameter is confirmed to meet the preset verification conditions, perform the operation of generating the length fusion feature based on the speed parameter and the duration fusion feature.

6. The system according to claim 1, characterized in that, The spacing between the at least two detection points along the transmission direction is configured to be associated with the standard axial length of a single paper cup.

7. The system according to claim 1, characterized in that, The feature fusion module is configured to process the independent occlusion duration signals from the at least two detection points, the processing including calculating the average value of the at least two independent occlusion duration signals to generate the interference-resistant duration fusion feature.

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