Multi-station collaborative work intelligent control method and system for vertical ampoule bottle making machine

Abstract

The application provides a vertical ampoule bottle making machine multi-station collaborative operation intelligent control method and system, relates to the technical field of ampoule bottle making machines, and comprises the following steps: acquiring a maximum temperature difference value, a pressure difference absolute value and a radial offset distance; constructing a first abnormal combination condition and a second abnormal combination condition; when the first abnormal combination condition and / or the second abnormal combination condition are satisfied, it is determined that the current glass tube blank has an abnormal positioning state at a sealing station, a first compensation value is determined, a first tolerance value is obtained according to the first compensation value and a standard sealing tolerance value; a second compensation value is determined, a second tolerance value is obtained according to the second compensation value and the standard sealing tolerance value; when the next glass tube blank reaches the sealing station, position correctness verification is performed according to the first tolerance value or the second tolerance value. On the premise of guaranteeing the sealing property and geometric precision of ampoule sealing, the comprehensive efficiency of the equipment is significantly improved, and the waste rate is reduced.

Description

Technical Field

[0001] This application relates to the field of ampoule bottle making machine technology, and in particular to a method and system for intelligent control of multi-station collaborative operation of vertical ampoule bottle making machine. Background Technology

[0002] In the production process of a vertical ampoule making machine, the glass preform flows sequentially through the heating station, forming station, and sealing station, each station having a crucial impact on the quality of the final product. However, in actual production, due to fluctuations in equipment operating conditions, improper process parameter settings, or environmental factors, some abnormal situations often occur, leading to incorrect positioning of the glass preform at the sealing station. Specifically, uneven temperature distribution in the heating station can cause differences in the degree of softening of the glass preform, resulting in preform deformation; asymmetrical pressure between the upper and lower molds in the forming station can lead to distortion of the preform's geometry, forming ellipses or eccentric circles. If these problems are not detected and corrected in time, they will directly affect the alignment accuracy of the sealing station, leading to poor sealing, such as poor sealing performance and unqualified appearance, seriously affecting product quality and production efficiency.

[0003] Traditional ampoule-making machines typically use a fixed tolerance threshold to determine if the sealing position is correct and simply reject products that do not meet the standards. While this method can identify some problematic products, it has the following shortcomings: First, it cannot distinguish between "abnormal supply conditions" (such as uneven temperature or pressure asymmetry) and "sealing mechanism malfunctions," making it prone to misjudgment or missed detections. Second, relying solely on a fixed tolerance threshold lacks a dynamic response mechanism to upstream process conditions, failing to prevent similar problems from occurring later. Finally, this passive rejection method not only increases the scrap rate but may also mask potential equipment malfunctions or process defects, leading to interruptions in continuous production and increased maintenance costs. Summary of the Invention

[0004] This application aims to at least partially address one of the technical problems in the related art.

[0005] To achieve the above objectives, this application proposes an intelligent control method for multi-station collaborative operation of a vertical ampoule making machine, comprising the following steps:

[0006] Step 1: The glass preform flows sequentially through the heating station, the forming station, and the sealing station, and the maximum temperature difference, the absolute value of the pressure difference, and the radial offset distance are obtained respectively; the absolute value of the pressure difference is obtained through the upper and lower molds;

[0007] Step 2: Based on the maximum temperature difference, the absolute value of the pressure difference, and the radial offset distance, construct a first abnormal combination condition and a second abnormal combination condition; wherein, the first abnormal combination condition is: the maximum temperature difference is greater than a preset upper limit value of the temperature gradient, and the radial offset distance is greater than the standard sealing tolerance value; the second abnormal combination condition is: the absolute value of the pressure difference is greater than a preset upper limit value of pressure asymmetry, and the radial offset distance is greater than the standard sealing tolerance value;

[0008] Step 3: When the first abnormal combination condition and / or the second abnormal combination condition are met, it is determined that the current glass blank has an abnormal positioning state at the sealing station, the current glass blank is rejected and the next step is executed.

[0009] Step 4: If the first abnormal combination is satisfied, a first compensation value is determined based on the maximum temperature difference and the preset upper limit of the temperature gradient, and a first tolerance value is obtained based on the first compensation value and the standard sealing tolerance value; if the second abnormal combination is satisfied, a second compensation value is determined based on the absolute value of the pressure difference and the preset upper limit of the pressure asymmetry, and a second tolerance value is obtained based on the second compensation value and the standard sealing tolerance value; if both the first and second abnormal combinations are satisfied, a third compensation value is obtained based on the first and second compensation values, and a third tolerance value is obtained based on the third compensation value and the standard sealing tolerance value.

[0010] Step 5: When the next glass tube blank arrives at the sealing station, verify the correctness of the position based on the first tolerance value, the second tolerance value, or the third tolerance value.

[0011] Furthermore, based on the heating station, the temperature values ​​of each temperature measuring point of the glass tube blank are collected, the temperature difference between adjacent temperature measuring points is determined, and the maximum temperature difference value is obtained based on the temperature difference value; based on the forming station, the closing pressure value of the upper mold and the closing pressure value of the lower mold are obtained through the upper and lower molds, and the absolute value of the pressure difference is obtained based on the closing pressure value of the upper mold and the closing pressure value of the lower mold; based on the sealing station, several frames of first and second images are obtained based on the sealing head and the end face of the glass tube blank, and the radial offset distance is obtained based on the first and second images.

[0012] Further, obtaining the radial offset distance based on the first image and the second image includes: performing fitting processing on the first image and the second image for each frame to obtain the first fitted center coordinates of the inner hole of the sealing head and the second fitted center coordinates of the glass tube blank end face; calculating the average value based on the first fitted center coordinates of all frames to obtain the center position of the sealing head; calculating the average value based on the second fitted center coordinates of all frames to obtain the center position of the tube blank end face; and obtaining the radial offset distance based on the center position of the sealing head and the center position of the tube blank end face.

[0013] Further, positional correctness verification is performed based on the first tolerance value, the second tolerance value, or the third tolerance value, including:

[0014] Step 51: Obtain the maximum temperature difference, absolute pressure difference, and radial offset distance of the next glass preform;

[0015] Step 52: Determine the count of consecutive abnormal events based on the first abnormal combination condition and / or the second abnormal combination condition;

[0016] Step 53: If the following sub-conditions are met, the verification is passed and the sealing process is performed; otherwise, the verification fails and the next glass preform is rejected. The sub-conditions are: the maximum temperature difference of the next glass preform is less than or equal to the preset upper limit of the temperature gradient, or the absolute value of the pressure difference of the next glass preform is less than or equal to the preset upper limit of the pressure asymmetry, and the radial offset distance of the next glass preform is less than or equal to the first tolerance value, the second tolerance value, or the third tolerance value.

[0017] Furthermore, after step 3 identifies that the first abnormal combination condition and / or the second abnormal combination condition are met, the temperature value and / or the upper mold closing pressure value or the lower mold closing pressure value of the heating station are adjusted respectively to obtain the target temperature value and / or the target pressure value.

[0018] Furthermore, when the first abnormal combination condition is met, the temperature value of the heating station is adjusted to obtain the target temperature value, including:

[0019] The target heating area is determined based on the temperature value; a local temperature value is determined based on the target heating area;

[0020] Determine the maximum and minimum temperature values ​​based on the stated temperature values;

[0021] The temperature of the target heating area is adjusted based on the maximum temperature value, the minimum temperature value, and the preset upper limit of the temperature gradient to obtain the temperature adjustment amount;

[0022] The target temperature value is obtained based on the local temperature value and the temperature adjustment amount.

[0023] Furthermore, when the second abnormal combination condition is met, the upper mold closing pressure value or the lower mold closing pressure value is adjusted to obtain the target pressure value, including: determining whether the upper mold closing pressure value and the lower mold closing pressure value are the same; if so, the process ends; otherwise, the pressure adjustment amount is calculated based on the upper mold closing pressure value and the lower mold closing pressure value, and the target pressure value is calculated based on the pressure adjustment amount and the upper mold closing pressure value or the lower mold closing pressure value.

[0024] Furthermore, when the first abnormal combination condition and the second abnormal combination condition are met simultaneously, the temperature value of the heating station, the upper mold closing pressure value, or the lower mold closing pressure value are adjusted simultaneously to obtain the target temperature value and the target pressure value.

[0025] This embodiment also discloses a multi-station collaborative intelligent control system for a vertical ampoule making machine, including the following modules:

[0026] Acquisition module: used to obtain the maximum temperature difference, absolute pressure difference, and radial offset distance; the absolute pressure difference is obtained through the upper and lower molds;

[0027] The construction module is used to construct a first abnormal combination condition and a second abnormal combination condition based on the maximum temperature difference, the absolute value of the pressure difference, and the radial offset distance. The first abnormal combination condition is that the maximum temperature difference is greater than a preset upper limit value for the temperature gradient, and the radial offset distance is greater than a standard sealing tolerance value. The second abnormal combination condition is that the absolute value of the pressure difference is greater than a preset upper limit value for pressure asymmetry, and the radial offset distance is greater than a standard sealing tolerance value.

[0028] Judgment module: When the first abnormal combination condition and / or the second abnormal combination condition are met, it determines that the current glass blank has an abnormal positioning state at the sealing station and rejects the current glass blank.

[0029] The compensation module is used to determine a first compensation value based on the maximum temperature difference and a preset upper limit of the temperature gradient, and to obtain a first tolerance value based on the first compensation value and a standard sealing tolerance value; if the second abnormal combination is satisfied, it determines a second compensation value based on the absolute value of the pressure difference and a preset upper limit of the pressure asymmetry, and to obtain a second tolerance value based on the second compensation value and a standard sealing tolerance value; if both the first and second abnormal combinations are satisfied, it obtains a third compensation value based on the first and second compensation values, and to obtain a third tolerance value based on the third compensation value and a standard sealing tolerance value.

[0030] Verification module: used to verify the correctness of the position when the next glass preform arrives at the sealing station, based on the first tolerance value, the second tolerance value, or the third tolerance value.

[0031] Compared with existing technologies, the intelligent control method and system for multi-station collaborative operation of the vertical ampoule bottle-making machine provided in this application synchronously collects and integrates three key cross-station parameters: the maximum temperature difference of the glass preform at the heating station, the absolute value of the pressure difference at the forming station, and the radial offset distance at the sealing station. This constructs a first abnormal combination condition (temperature gradient exceeding limits and sealing offset exceeding limits) and a second abnormal combination condition (pressure asymmetry exceeding limits and sealing offset exceeding limits), thus completely abandoning the crude control mode of traditional bottle-making equipment that relies solely on a single parameter for threshold alarms. The essence of this combined criterion lies in introducing the principle of dual evidence: incorrect sealing position (result) must occur simultaneously with a specific abnormal upstream process state (cause) to be judged as a systematic deviation caused by supply quality problems, rather than accidental disturbances or malfunctions of the sealing mechanism itself. If only the sealing offset exceeds the limit but the temperature and pressure are normal, it may be attributed to mechanical offset of the sealing head or visual measurement noise; conversely, if the temperature gradient significantly exceeds the limit but the sealing offset is still within the tolerance, it indicates that the current disturbance has not yet affected the final alignment, and no intervention is required. Only when the cause and effect coexist can we confirm the existence of typical abnormal supply situations, such as thermal deformation of the tube blank due to uneven heating during feeding, or geometric misroundness due to unbalanced forming forces, thereby accurately pinpointing the root cause of the anomaly. This application significantly reduces the rate of false rejections and missed inspections, improving the yield rate while ensuring sealing quality.

[0032] When this application triggers the first abnormal combination condition and / or the second abnormal combination condition, it not only calculates the target temperature value of the target heating area based on the temperature value and the preset upper limit value of the temperature gradient, but also calculates the target pressure value based on the upper mold closing pressure value and the lower mold closing pressure value. At the same time, based on the maximum temperature difference value, the radial offset distance and the absolute value of the pressure difference, as well as the upper limit value of the temperature gradient and the upper limit value of the pressure asymmetry under the abnormal combination condition, it compensates for the standard sealing tolerance value; and applies the target temperature value, the compensated standard sealing tolerance value and the target pressure value to the production process of the next glass preform. By proactively adjusting heating and forming parameters, defects in the tube blank that cause sealing misalignment are suppressed at the source, improving process stability. Dynamic compensation of tolerances prevents qualified products from being mistakenly rejected due to short-term disturbances, balancing quality control and production efficiency. More importantly, the coordinated adjustment of temperature, pressure, and tolerance ensures the systematic and consistent nature of the control strategy, preventing quality risks caused by excessively relaxed standards and avoiding capacity losses due to mechanically applying stringent thresholds. Thus, while ensuring the sealing performance and geometric accuracy of ampoules, the overall efficiency of the equipment is significantly improved, the scrap rate is reduced, and reliable support is provided for the continuous intelligent manufacturing of highly consistent pharmaceutical glass containers.

[0033] The core of this application lies in achieving deep collaborative cooperation among the three major workstations: heating, forming, and sealing. The sealing workstation no longer judges positional accuracy in isolation; instead, it jointly analyzes the detected radial offset with the temperature distribution of the upstream heating workstation and the pressure status of the forming workstation. A collaborative response is triggered only when a specific upstream anomaly and sealing offset occur simultaneously. At this point, precise adjustment commands are sent upstream to dynamically correct the target temperature of the heating zone or the target pressure of the mold, improving the supply quality of the next preform from the source. Simultaneously, the judgment tolerance of the sealing workstation is adjusted to match the current process state. The adjusted parameters and compensated tolerance work together on the following glass preform, ensuring high consistency between upstream and downstream processes. This control mechanism, linked by the cause of anomalies, targeting the same preform, and executing synchronously across workstations, truly achieves integrated intelligent control of multiple workstations, significantly improving the overall coordination and response efficiency of the system. Attached Figure Description

[0034] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein:

[0035] Figure 1 A flowchart illustrating the intelligent control method for multi-station collaborative operation of a vertical ampoule making machine provided in this application embodiment;

[0036] Figure 2 A flowchart illustrating the multi-station collaborative intelligent control system for the vertical ampoule making machine provided in this application embodiment;

[0037] Figure 3 This is a block diagram of an electronic device provided in an embodiment of this application. Detailed Implementation

[0038] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0039] The following description, with reference to the accompanying drawings, describes an intelligent control method and system for multi-station collaborative operation of a vertical ampoule making machine according to embodiments of this application.

[0040] like Figure 1 As shown, the intelligent control method for multi-station collaborative operation of a vertical ampoule bottle making machine includes the following steps:

[0041] Step 1: The glass preform flows sequentially through the heating station, forming station and sealing station, and the maximum temperature difference, absolute pressure difference and radial offset distance are obtained respectively.

[0042] Based on the heating station, temperature values ​​at various temperature measuring points of the glass tube blank are collected, and the temperature difference between adjacent temperature measuring points is determined. The maximum temperature difference value is obtained based on the temperature difference value. The absolute value of the pressure difference is obtained through the upper and lower molds: Based on the forming station, the closing pressure values ​​of the upper mold and the lower mold are obtained through the upper and lower molds, and the absolute value of the pressure difference is obtained based on the closing pressure values ​​of the upper mold and the lower mold. Based on the sealing station, several frames of first and second images are obtained based on the sealing head and the end face of the glass tube blank, and the radial offset distance is obtained based on the first and second images. Obtaining the radial offset distance based on the first and second images includes: performing fitting processing on each frame of the first and second images to obtain the first fitted circle center coordinates of the inner hole of the sealing head and the second fitted circle center coordinates of the end face of the glass tube blank; calculating the average value based on the first fitted circle center coordinates of all frames to obtain the center position of the sealing head; calculating the average value based on the second fitted circle center coordinates of all frames to obtain the center position of the end face of the tube blank; and obtaining the radial offset distance based on the center position of the sealing head and the center position of the end face of the tube blank.

[0043] In this embodiment, the glass preform sequentially passes through the heating station, forming station, and sealing station of the vertical ampoule making machine. The heating station of the vertical ampoule making machine has a heating chamber extending axially along the glass preform, the length of which matches that of a standard glass preform (e.g., 80 mm). Inside this heating chamber, five infrared temperature sensors are fixedly mounted on the frame at equal intervals, facing the outer wall of the glass preform, corresponding to five fixed axial positions from bottom to top of the preform, and collecting the temperature values ​​at each position in real time. The temperature difference between adjacent temperature measurement points is calculated, and the maximum temperature difference is determined. Subsequently, the glass preform enters the forming station. During the closing process of the upper and lower molds, pressure sensors measure the closing pressure values ​​of the upper and lower molds, respectively, and the absolute value of the pressure difference is calculated from this. When the tube blank arrives at the sealing station, before the sealing heating is started, a high frame rate industrial camera continuously acquires 10 frames of images. Odd-numbered frames are used to capture the inner hole contour of the sealing head (first image), and even-numbered frames are used to capture the end face contour of the glass tube blank (second image). Edge extraction and circle fitting are performed on each frame to obtain the coordinates of the inner hole center of the sealing head (first fitted center) and the center coordinates of the end face of the tube blank (second fitted center) for each frame. Then, the average of the five first fitted center coordinates in the 10 frames is taken as the center position of the sealing head, and the average of the five second fitted center coordinates is taken as the center position of the end face of the tube blank. Finally, the Euclidean distance between the two is calculated to obtain the radial offset distance.

[0044] Step 2: Based on the maximum temperature difference, the absolute value of the pressure difference, and the radial offset distance, construct a first abnormal combination condition and a second abnormal combination condition; wherein, the first abnormal combination condition is: the maximum temperature difference is greater than the preset upper limit of the temperature gradient, and the radial offset distance is greater than the standard sealing tolerance value; the second abnormal combination condition is: the absolute value of the pressure difference is greater than the preset upper limit of the pressure asymmetry, and the radial offset distance is greater than the standard sealing tolerance value.

[0045] In this embodiment, the preset upper limit of temperature gradient is 30°C, the upper limit of pressure asymmetry is 0.5 MPa, and the standard sealing tolerance is 0.3 mm.

[0046] Step 3: When the first abnormal combination condition and / or the second abnormal combination condition are met, it is determined that the current glass blank has an abnormal positioning state at the sealing station, the current glass blank is rejected and the next step is executed.

[0047] In this embodiment, when the maximum temperature difference exceeds the preset upper limit of the temperature gradient and the radial offset distance exceeds the standard sealing tolerance, the first abnormal combination condition is determined to be met. This confirms that the tube blank's uneven temperature distribution at the heating station leads to asymmetrical thermal softening, resulting in sealing positioning deviation. Simultaneously, if the absolute value of the pressure difference is greater than the preset upper limit of pressure asymmetry and the radial offset distance also exceeds 0.3 mm, the second abnormal combination condition is met. This indicates that the upper and lower molds at the forming station are under unbalanced forces, causing tube blank roundness defects and affecting sealing alignment. As long as any of the above combination conditions is met, it is determined that the abnormal positioning state of the current glass tube blank at the sealing station originates from abnormal supply from the upstream station, rather than a mechanical failure of the sealing mechanism itself. The rejection mechanism is then activated to guide the tube blank to the scrap channel, and a multi-station collaborative response mechanism is simultaneously triggered to prepare for the control and verification of the next glass tube blank. By establishing a causal relationship between the geometric deviation at the sealing end and key process parameters in the heating and forming stages, a leap from phenomenon identification to root cause classification is achieved. This effectively avoids the false rejection, missed judgment, or invalid alarms caused by the isolated reliance on a single threshold in traditional methods, and significantly improves the accuracy of abnormal response and the overall intelligence level of the system.

[0048] Furthermore, in this embodiment (step 3), after identifying that the first abnormal combination condition and / or the second abnormal combination condition are met, the temperature value and / or the upper mold closing pressure value or the lower mold closing pressure value of the heating station are adjusted respectively to obtain the target temperature value and / or the target pressure value.

[0049] Compared to existing technologies that passively reject defects only at the sealing station or fine-tune upstream parameters to fixed values, this embodiment, upon identifying the fulfillment of the first and / or second abnormal combination conditions, can proactively calculate and set the target temperature value for the heating station and / or the target pressure value for the forming station based on the cause of the anomaly. This achieves precise feedforward control for the next glass preform, representing a significant technological advancement. By binding the sealing offset to specific upstream conditions (such as temperature gradients and pressure differences), this embodiment immediately drives the corresponding actuator to output a quantitative adjustment signal upon confirming the anomaly type, ensuring that the next preform completes heating and forming under optimized process conditions, thus suppressing defect propagation at its source. This integrated identification-attribution-adjustment mechanism not only significantly shortens fault recovery time but also avoids secondary disturbances caused by blind adjustments, truly realizing intelligent linkage and closed-loop management between multiple stations, and significantly improving the equipment's adaptability, product quality stability, and automation level.

[0050] When the first abnormal combination condition is met, the temperature value of the heating station is adjusted to obtain the target temperature value, including:

[0051] The target heating area is determined based on the temperature value.

[0052] The glass tube blank is divided into four equal-length sections along its axis, with five temperature measuring points located sequentially as follows: Temperature measuring point 1: located at the bottom of the tube blank (approximately 5 mm from the bottom), defined as the bottom region; Temperature measuring point 2: located at the lower 1 / 4 of the tube blank (approximately 20 mm from the bottom), defined as the lower region; Temperature measuring point 3: located in the middle of the tube blank (approximately 40 mm from the bottom), defined as the middle region; Temperature measuring point 4: located at the upper 1 / 4 of the tube blank (approximately 60 mm from the bottom), defined as the upper region; Temperature measuring point 5: located at the top of the tube blank (approximately 75 mm from the bottom), defined as the top region. Correspondingly, the heating station is physically divided into two independent temperature-controlled sections: the lower heating zone: covering the lower tube blank regions corresponding to temperature measuring points 1 and 2; the upper heating zone: covering the upper tube blank regions corresponding to temperature measuring points 4 and 5; Temperature measuring point 3 is located at the boundary between the two heating zones, and its data is used to assist in determining the temperature gradient trend, but it is not assigned to any single heating zone.

[0053] After collecting the real-time temperatures of each temperature measurement point, the average temperature of the corresponding temperature measurement points (points 1 and 2) in the front heating zone and the average temperature of the corresponding temperature measurement points (points 4 and 5) in the rear heating zone are calculated and compared. If the average temperature of the rear zone is higher than that of the front zone, and the overall maximum temperature occurs at point 4 or point 5, then the rear heating zone is determined to be the area with the highest current temperature, which is the target heating area; otherwise, the front zone is determined to be the high-temperature zone.

[0054] The local temperature value is determined based on the average temperature value of the target heating area.

[0055] The maximum temperature value Tmax and the minimum temperature value Tmin are determined based on the temperature values.

[0056] Based on the maximum temperature value, the minimum temperature value, and the preset upper limit of the temperature gradient T0, the temperature of the target heating area is adjusted to obtain the temperature adjustment amount P1; the target temperature value is obtained based on the local temperature value and the temperature adjustment amount.

[0057] P1 = k1 × (Tmax - Tmin - T0), where k1 is the temperature coefficient, preferably 1%. The target temperature value is obtained by subtracting the local temperature value from the temperature adjustment amount.

[0058] When the second abnormal combination condition is met, the upper die closing pressure value or the lower die closing pressure value is adjusted to obtain the target pressure value, including: determining whether the upper die closing pressure value and the lower die closing pressure value are the same; if so, the process ends; otherwise, the pressure adjustment amount is calculated based on the upper die closing pressure value and the lower die closing pressure value, and the target pressure value is calculated based on the pressure adjustment amount and the upper die closing pressure value or the lower die closing pressure value.

[0059] In this embodiment, when the second abnormal combination condition is triggered, the closing pressure values ​​of the upper mold and the lower mold in the current forming station are first obtained, and it is determined whether they are equal. If they are not equal, it indicates that there is an asymmetry in the force distribution between the upper and lower molds during the closing process. Based on the magnitude of the deviation between these two pressure values, the pressure adjustment amount is calculated by multiplying it by the compensation coefficient calibrated by the equipment to balance the force distribution between the upper and lower molds. Subsequently, based on the pressure adjustment amount and the closing pressure value of the higher or lower side, the target pressure value required by the hydraulic actuator on the corresponding side is determined. For example, if the upper mold pressure is higher than the lower mold pressure, the upper mold pressure is lowered by the pressure adjustment amount to obtain the target pressure value of the upper mold; or, the lower mold pressure can be increased to obtain the target pressure value of the lower mold. This target pressure value will be used as a new control setting and applied to the forming cycle of the next glass preform, thereby correcting the force balance of the mold, improving the consistency of the preform geometry, and providing more stable supply conditions for the subsequent sealing station.

[0060] When the first abnormal combination condition and the second abnormal combination condition are met simultaneously, the temperature value of the heating station, the upper mold closing pressure value, or the lower mold closing pressure value are adjusted to obtain the target temperature value and the target pressure value.

[0061] Step 4: If the first abnormal combination is satisfied, a first compensation value is determined based on the maximum temperature difference and the preset upper limit of the temperature gradient, and a first tolerance value is obtained based on the first compensation value and the standard sealing tolerance value; if the second abnormal combination is satisfied, a second compensation value is determined based on the absolute value of the pressure difference and the preset upper limit of the pressure asymmetry, and a second tolerance value is obtained based on the second compensation value and the standard sealing tolerance value; if both the first and second abnormal combinations are satisfied, a third compensation value is obtained based on the first and second compensation values, and a third tolerance value is obtained based on the third compensation value and the standard sealing tolerance value.

[0062] In this embodiment, a first compensation value is calculated by multiplying the difference between the maximum temperature difference and the preset upper limit of the temperature gradient by a preset temperature compensation coefficient. This first compensation value is then added to the standard sealing tolerance value to obtain the first tolerance value used for the verification of the next glass preform. Similarly, when the second abnormal combination condition is met, the difference between the absolute value of the pressure difference and the preset upper limit of pressure asymmetry is multiplied by a preset pressure compensation coefficient to obtain the second compensation value. This second compensation value is then added to the standard sealing tolerance value to form the second tolerance value. If both types of abnormalities occur simultaneously, the first and second compensation values ​​are calculated separately and then added together to obtain the third compensation value. This third compensation value is then added to the standard sealing tolerance value to finally obtain the third tolerance value. This achieves the quantification and dynamic adjustment of the sealing judgment standard, responding to the degree of upstream disturbance while ensuring the rationality of quality control.

[0063] Step 5: When the next glass preform arrives at the sealing station, verify the correctness of the position according to the first tolerance value, the second tolerance value, or the third tolerance value, including:

[0064] Step 51: Obtain the maximum temperature difference, absolute pressure difference, and radial offset distance of the next glass preform.

[0065] In this embodiment, the maximum temperature difference, absolute pressure difference, and radial offset distance of the next glass preform are all data actually measured under process conditions where the previous abnormal response has taken effect. Specifically, after the previous preform is rejected due to an abnormality, the heating station has adjusted the heat output of the corresponding heating area according to the calculated target temperature value, and the forming station has also corrected the closing pressure of the upper and lower molds according to the target pressure value. When the next glass preform passes through the heating, forming, and sealing stations in sequence, the temperature at each axial position during the heating process is collected in real time to determine the maximum temperature difference. At the same time, the actual closing pressure of the upper and lower molds is obtained during the forming process, and the absolute value of the difference between the two is calculated. Finally, at the sealing station, the center offset between the preform end face and the sealing head is measured by visual imaging to obtain the radial offset distance. These parameters truly reflect the actual production state after temperature and pressure adjustments have been implemented, ensuring that the data used for subsequent verification is consistent with the current process conditions, thereby achieving accurate and reliable sealing quality judgment.

[0066] Step 52: Determine the count of consecutive abnormal events based on the first abnormal combination condition and / or the second abnormal combination condition.

[0067] The maximum temperature difference, absolute pressure difference, and radial offset distance of the current glass blank are substituted into the first and second abnormal combination conditions for judgment. If either combination condition is met, the current blank is determined to be in an abnormal state, and the continuous abnormal event counter is incremented by 1. If neither combination condition is met, the abnormality is considered to have been eliminated, and the counter is reset to zero. For example, if a previous blank was rejected due to the first abnormal combination, and the current blank again simultaneously meets the temperature gradient and sealing offset limits, the continuous abnormal event count is updated to 2; if subsequent blanks return to normal, the count is reset to zero. This count value is used to evaluate the effectiveness of the adjustment measures. When the count reaches a preset threshold (e.g., 3 consecutive abnormalities), an enhanced adjustment strategy or equipment warning can be triggered to prevent the continued occurrence of ineffective control. Through this mechanism, the system not only focuses on single abnormalities but also dynamically tracks the persistence of abnormalities, providing a time-series judgment basis for intelligent decision-making.

[0068] Step 53: If the following sub-conditions are met, the verification is passed and the sealing process is performed; otherwise, the verification fails and the next glass preform is rejected. The sub-conditions are: the maximum temperature difference of the next glass preform is less than or equal to the preset upper limit of the temperature gradient, or the absolute value of the pressure difference of the next glass preform is less than or equal to the preset upper limit of the pressure asymmetry, and the radial offset distance of the next glass preform is less than or equal to the first tolerance value, the second tolerance value, or the third tolerance value.

[0069] The current glass preform must simultaneously meet two conditions: First, its maximum temperature difference must not exceed the preset upper limit of the temperature gradient, or its absolute pressure difference must not exceed the preset upper limit of the pressure asymmetry. Second, its radial offset distance must not exceed the currently effective dynamic tolerance value, which is determined based on the type of previous anomaly. If only the first anomaly combination was triggered previously, the first tolerance value is used; if only the second anomaly combination was triggered, the second tolerance value is used; if both anomalies occur simultaneously, the third tolerance value is used. For example, assuming the first tolerance value was activated due to a previous temperature anomaly, the current preform measures a maximum temperature difference of 28°C, an absolute pressure difference of 0.6 MPa, and a radial offset distance of 0.40 mm. Since the temperature difference meets the "OR" condition and the offset distance does not exceed the tolerance, both sub-conditions are met, the verification is deemed successful, and sealing is permitted. Conversely, if both temperature and pressure exceed the limits, or the offset distance exceeds the corresponding tolerance value, the verification is deemed unsuccessful, and the rejection mechanism is activated to discharge the preform. This verification logic, while ensuring sealing quality, allows for controllable deviations caused by single process disturbances, avoids excessive rejection, and significantly improves the system's adaptability to short-term fluctuations and production continuity.

[0070] It is important to note that the first, second, or third tolerance values ​​generated in this application are temporary tolerance values, effective only for the "next glass blank" immediately following the abnormal blank, and not continuously applied to all subsequent blanks. This temporary tolerance value is a dynamic judgment threshold set after identifying upstream process disturbances (such as uneven heating or pressure imbalance) to reasonably assess the sealing status of the first responding blank under the new operating conditions where adjustment measures have been implemented. If the next blank passes verification, it indicates that the adjustment is effective, and the standard sealing tolerance value is automatically restored for judging subsequent blanks; if verification fails, it is rejected. This tolerance mechanism avoids the quality risks caused by fixed, relaxed standards and prevents frequent erroneous rejection of qualified products, ensuring a balance between the rigor of quality control and the flexibility of the production process.

[0071] This embodiment does not require the next glass preform to fully recover in all dimensions. Instead, it allows for a more reasonable assessment of radial offset, provided that at least one of the temperature or pressure has returned to normal, by combining a temporary tolerance value (first, second, or third tolerance value) that matches the type of preceding anomaly. This prevents qualified products from being mistakenly rejected due to short-term fluctuations in a single parameter, while ensuring that quality requirements are not relaxed due to the simultaneous presence of two upstream anomalies. Furthermore, the temporary tolerance value only applies to the first responding preform after adjustment, avoiding the quality risks associated with long-term relaxation of standards.

[0072] This embodiment also includes a control unit, the core of which is a central controller. This controller is used to: collect and cache multi-point temperature data from the heating station, upper and lower mold closing pressure data from the forming station, and visual image information from the sealing station in real time; perform anomaly detection, process parameter adjustment, and tolerance threshold calculation based on preset abnormal combination conditions and dynamic compensation algorithms; and coordinate the timing of actions of the rejection mechanism, heating device, and forming mold. It is precisely this highly integrated central controller that enables the system to achieve millisecond-level data processing and decision response during the glass preform flow. Specifically, when the preform enters the sealing station but before the sealing heating and pressing actions are initiated, the central controller has already used the temperature and pressure data synchronously acquired during the heating and forming stages, combined with the multi-frame image analysis results completed by the high-speed camera at the sealing station during the pre-alignment stage (typically within 200–500 milliseconds), to quickly calculate the radial offset distance and complete all logical judgments in step 3 or step 53. Since all sensing, calculation and execution instructions are completed in parallel within the inherent cycle time of the equipment, and there is no need to wait for the sealing process to end, this application can ensure that the abnormal judgment and rejection decision of the current or next billet is completed before the actual sealing action is executed, truly realizing the timely response mechanism of judgment before sealing and no sealing of defects, effectively avoiding energy waste, mold contamination and quality risks caused by ineffective sealing.

[0073] like Figure 2 As shown, this embodiment also discloses a multi-station collaborative intelligent control system for a vertical ampoule making machine, including the following modules:

[0074] Acquisition module: used to obtain the maximum temperature difference, absolute pressure difference, and radial offset distance; the absolute pressure difference is obtained through the upper and lower molds;

[0075] The construction module is used to construct a first abnormal combination condition and a second abnormal combination condition based on the maximum temperature difference, the absolute value of the pressure difference, and the radial offset distance. The first abnormal combination condition is that the maximum temperature difference is greater than a preset upper limit value for the temperature gradient, and the radial offset distance is greater than a standard sealing tolerance value. The second abnormal combination condition is that the absolute value of the pressure difference is greater than a preset upper limit value for pressure asymmetry, and the radial offset distance is greater than a standard sealing tolerance value.

[0076] Judgment module: When the first abnormal combination condition and / or the second abnormal combination condition are met, it determines that the current glass blank has an abnormal positioning state at the sealing station and rejects the current glass blank.

[0077] The compensation module is used to determine a first compensation value based on the maximum temperature difference and a preset upper limit of the temperature gradient, and to obtain a first tolerance value based on the first compensation value and a standard sealing tolerance value; if the second abnormal combination is satisfied, it determines a second compensation value based on the absolute value of the pressure difference and a preset upper limit of the pressure asymmetry, and to obtain a second tolerance value based on the second compensation value and a standard sealing tolerance value; if both the first and second abnormal combinations are satisfied, it obtains a third compensation value based on the first and second compensation values, and to obtain a third tolerance value based on the third compensation value and a standard sealing tolerance value.

[0078] Verification module: used to verify the correctness of the position when the next glass preform arrives at the sealing station, based on the first tolerance value, the second tolerance value, or the third tolerance value.

[0079] To implement the above embodiments, this application also proposes an electronic device. Please see [link to relevant documentation]. Figure 3 , Figure 3 This is a schematic diagram of the structure of the electronic device provided in an embodiment of this application. For example... Figure 3 As shown, the electronic device 500 includes: a processor 501 and a memory 502 communicatively connected to the processor 501; the memory 502 stores computer-executable instructions; the processor 501 executes the computer-executable instructions stored in the memory to implement the method provided in the foregoing embodiments.

[0080] To implement the above embodiments, this application also proposes a computer-readable storage medium storing computer-executable instructions, which, when executed by a processor, are used to implement the methods provided in the foregoing embodiments.

[0081] To implement the above embodiments, this application also proposes a computer program product, including a computer program that, when executed by a processor, implements the methods provided in the foregoing embodiments.

[0082] The storage medium mentioned above can be a read-only memory, a disk, or an optical disk, etc. Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of this application.

Claims

1. A multi-station collaborative intelligent control method for a vertical ampoule making machine, characterized in that: Includes the following steps: Step 1: The glass preform flows sequentially through the heating station, the forming station, and the sealing station, and the maximum temperature difference, the absolute value of the pressure difference, and the radial offset distance are obtained respectively; the absolute value of the pressure difference is obtained through the upper and lower molds; Step 2: Based on the maximum temperature difference, the absolute value of the pressure difference, and the radial offset distance, construct a first abnormal combination condition and a second abnormal combination condition; wherein, the first abnormal combination condition is: the maximum temperature difference is greater than a preset upper limit value of the temperature gradient, and the radial offset distance is greater than the standard sealing tolerance value; the second abnormal combination condition is: the absolute value of the pressure difference is greater than a preset upper limit value of pressure asymmetry, and the radial offset distance is greater than the standard sealing tolerance value; Step 3: When the first abnormal combination condition and / or the second abnormal combination condition are met, it is determined that the current glass blank has an abnormal positioning state at the sealing station, the current glass blank is rejected and the next step is executed; after the first abnormal combination condition and / or the second abnormal combination condition are identified, the temperature value and / or the upper mold closing pressure value or the lower mold closing pressure value of the heating station are adjusted respectively to obtain the target temperature value and / or the target pressure value. Step 4: If the first abnormal combination is satisfied, a first compensation value is determined based on the maximum temperature difference and the preset upper limit of the temperature gradient, and a first tolerance value is obtained based on the first compensation value and the standard sealing tolerance value; if the second abnormal combination is satisfied, a second compensation value is determined based on the absolute value of the pressure difference and the preset upper limit of the pressure asymmetry, and a second tolerance value is obtained based on the second compensation value and the standard sealing tolerance value; if both the first and second abnormal combinations are satisfied, a third compensation value is obtained based on the first and second compensation values, and a third tolerance value is obtained based on the third compensation value and the standard sealing tolerance value. Step 5: When the next glass preform arrives at the sealing station, verify the correctness of the position according to the first tolerance value, the second tolerance value, or the third tolerance value, including: Step 51: Obtain the maximum temperature difference, absolute pressure difference, and radial offset distance of the next glass preform; Step 52: Determine the count of consecutive abnormal events based on the first abnormal combination condition and / or the second abnormal combination condition; Step 53: If the following sub-conditions are met, the verification is passed and the sealing process is performed; otherwise, the verification fails and the next glass preform is rejected. The sub-conditions are: the maximum temperature difference of the next glass preform is less than or equal to the preset upper limit of the temperature gradient, or the absolute value of the pressure difference of the next glass preform is less than or equal to the preset upper limit of the pressure asymmetry, and the radial offset distance of the next glass preform is less than or equal to the first tolerance value, the second tolerance value, or the third tolerance value.

2. The intelligent control method for multi-station collaborative operation of the vertical ampoule bottle making machine according to claim 1, characterized in that, Based on the heating station, the temperature values ​​of each temperature measuring point of the glass tube blank are collected, the temperature difference between adjacent temperature measuring points is determined, and the maximum temperature difference value is obtained based on the temperature difference value; based on the forming station, the closing pressure value of the upper mold and the closing pressure value of the lower mold are obtained through the upper and lower molds, and the absolute value of the pressure difference is obtained based on the closing pressure value of the upper mold and the closing pressure value of the lower mold; based on the sealing station, several frames of first and second images are obtained based on the sealing head and the end face of the glass tube blank, and the radial offset distance is obtained based on the first and second images.

3. The intelligent control method for multi-station collaborative operation of the vertical ampoule bottle making machine according to claim 2, characterized in that, The radial offset distance is obtained based on the first image and the second image, including: performing fitting processing on the first image and the second image in each frame to obtain the first fitted center coordinates of the inner hole of the sealing head and the second fitted center coordinates of the glass tube blank end face; calculating the average value based on the first fitted center coordinates of all frames to obtain the center position of the sealing head; calculating the average value based on the second fitted center coordinates of all frames to obtain the center position of the tube blank end face; and obtaining the radial offset distance based on the center position of the sealing head and the center position of the tube blank end face.

4. The intelligent control method for multi-station collaborative operation of the vertical ampoule bottle making machine according to claim 1, characterized in that, When the first abnormal combination condition is met, the temperature value of the heating station is adjusted to obtain the target temperature value, including: The target heating area is determined based on the temperature value; a local temperature value is determined based on the target heating area; Determine the maximum and minimum temperature values ​​based on the stated temperature values; The temperature of the target heating area is adjusted based on the maximum temperature value, the minimum temperature value, and the preset upper limit of the temperature gradient to obtain the temperature adjustment amount; The target temperature value is obtained based on the local temperature value and the temperature adjustment amount.

5. The intelligent control method for multi-station collaborative operation of a vertical ampoule bottle-making machine according to claim 4, characterized in that, When the second abnormal combination condition is met, the upper die closing pressure value or the lower die closing pressure value is adjusted to obtain the target pressure value, including: determining whether the upper die closing pressure value and the lower die closing pressure value are the same; if so, the process ends; otherwise, the pressure adjustment amount is calculated based on the upper die closing pressure value and the lower die closing pressure value, and the target pressure value is calculated based on the pressure adjustment amount and the upper die closing pressure value or the lower die closing pressure value.

6. The intelligent control method for multi-station collaborative operation of a vertical ampoule bottle-making machine according to claim 5, characterized in that, When the first abnormal combination condition and the second abnormal combination condition are met simultaneously, the temperature value of the heating station, the upper mold closing pressure value, or the lower mold closing pressure value are adjusted to obtain the target temperature value and the target pressure value.

7. A multi-station collaborative intelligent control system for a vertical ampoule making machine, used to execute the multi-station collaborative intelligent control method for a vertical ampoule making machine as described in any one of claims 1-6, characterized in that, Includes the following modules: Acquisition module: used to obtain the maximum temperature difference, absolute pressure difference, and radial offset distance; the absolute pressure difference is obtained through the upper and lower molds; The construction module is used to construct a first abnormal combination condition and a second abnormal combination condition based on the maximum temperature difference, the absolute value of the pressure difference, and the radial offset distance. The first abnormal combination condition is that the maximum temperature difference is greater than a preset upper limit value for the temperature gradient, and the radial offset distance is greater than a standard sealing tolerance value. The second abnormal combination condition is that the absolute value of the pressure difference is greater than a preset upper limit value for pressure asymmetry, and the radial offset distance is greater than a standard sealing tolerance value. Judgment module: When the first abnormal combination condition and / or the second abnormal combination condition are met, it determines that the current glass blank has an abnormal positioning state at the sealing station and rejects the current glass blank. The compensation module is used to determine a first compensation value based on the maximum temperature difference and a preset upper limit of the temperature gradient, and to obtain a first tolerance value based on the first compensation value and a standard sealing tolerance value; if the second abnormal combination is satisfied, it determines a second compensation value based on the absolute value of the pressure difference and a preset upper limit of the pressure asymmetry, and to obtain a second tolerance value based on the second compensation value and a standard sealing tolerance value; if both the first and second abnormal combinations are satisfied, it obtains a third compensation value based on the first and second compensation values, and to obtain a third tolerance value based on the third compensation value and a standard sealing tolerance value. Verification module: used to verify the correctness of the position when the next glass preform arrives at the sealing station, based on the first tolerance value, the second tolerance value, or the third tolerance value.

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