Precise molding control method and system for silicone rubber glass fiber sleeve

Abstract

The invention relates to the field of composite material forming, and discloses a precise forming control method and system for a silicon rubber glass fiber casing pipe, and the method comprises the steps: taking an initial production process of a target casing pipe as a starting point, firstly determining a slurry infiltration interface and analyzing a rheological behavior mode, and then detecting a real-time deformation state of the casing pipe in a forming production line in combination with the mode; analyzing heat conduction characteristics of the fiber-rubber composite structure and each bonding layer, quantifying a heat accumulation effect value in a vulcanization scene based on the heat conduction characteristics, and calculating a thermal stress degree value of each vulcanization stage, so as to determine an optimal cross-linking process, detect a corresponding material effect item, optimize a pressure gradient value in an impregnation pressure field, and improve the heat conduction performance of the fiber-rubber composite structure. And finally, forming process parameters are optimized according to the pressure gradient value, optimized process elements are recognized, and finally a precise parameter control scheme for casing forming is formulated. The forming precision and reliability of the silicone rubber glass fiber sleeve can be improved.

Description

Technical Field

[0001] This invention relates to a precision molding control method and system for silicone rubber glass fiber sleeves, belonging to the field of composite material molding. Background Technology

[0002] Silicone rubber fiberglass sleeves are a key insulating and protective component, widely used in the protection of wires and cables in harsh environments such as high temperature and high humidity. Their molding precision directly determines the uniformity of the sleeve wall thickness, the interfacial bonding strength, and the pressure resistance and mechanical properties of the final product.

[0003] Currently, the molding and production of this type of sleeve is generally controlled by pre-set process parameters. For example, based on material formulation and experience, key indicators such as impregnation speed, vulcanization temperature and time are fixed. However, this static control mode cannot effectively perceive and adapt to the dynamic changes in slurry viscosity during the production process, the complex interaction between fiber structure and rubber matrix during the high-temperature vulcanization stage, and the resulting uneven distribution of internal stress. This can easily lead to defects such as poor impregnation, microbubbles, warping or over-vulcanization in the sleeve, which seriously affects the consistency and reliability of the product and becomes a bottleneck for the large-scale production of high-precision sleeves. Summary of the Invention

[0004] This invention provides a method and system for precision molding control of silicone rubber glass fiber sleeves, the main purpose of which is to improve the molding accuracy and reliability of silicone rubber glass fiber sleeves.

[0005] To achieve the above objectives, the present invention provides a method for precision molding and control of silicone rubber glass fiber sleeves, comprising:

[0006] Obtain the initial production process corresponding to the target casing, determine the slurry wetting interface corresponding to the target casing based on the initial production process, and analyze the rheological behavior mode corresponding to the slurry wetting interface. Based on the rheological behavior pattern, the real-time deformation state of the target sleeve in the preset molding production line is detected. Based on the real-time deformation state, the fiber-rubber composite structure of the target sleeve is analyzed, and the thermal conductivity characteristics of each bonding layer in the fiber-rubber composite structure are detected. Based on the aforementioned heat conduction characteristics, the heat accumulation effect value of the target sleeve under the vulcanization scenario is quantified, and based on the heat accumulation effect value, the thermal stress level value of the target sleeve at each vulcanization stage is calculated. Based on the thermal stress level, the optimal crosslinking process of the target sleeve in the molding production line is determined, the material effect term corresponding to the optimal crosslinking process is detected, and the pressure gradient value of the target sleeve in the preset impregnation pressure field is optimized based on the material effect term. Based on the pressure gradient value, the forming process parameters corresponding to the target sleeve are optimized, the optimized process elements in the optimized forming process parameters are identified, and based on the optimized process elements, a parameter control scheme for the forming precision of the target sleeve is formulated.

[0007] Optionally, determining the optimal crosslinking process for the target sleeve in the molding line based on the thermal stress level value includes: Based on the stated thermal stress level values, analyze the thermal stress distribution at each vulcanization stage; Based on the aforementioned thermal stress distribution, query the stress concentration area of ​​the current crosslinking process; For the stress concentration area, adjust the temperature setting of the vulcanizing equipment in the molding production line; Based on the adjusted temperature settings, the vulcanization time for each vulcanization stage is redistributed. By integrating the temperature setting and the vulcanization time, the optimal crosslinking process for the target sleeve in the molding production line is determined.

[0008] Optionally, adjusting the temperature setting of the vulcanizing equipment in the molding production line for the stress concentration area includes: Analyze the regional distribution details corresponding to the stress concentration area; Based on the detailed regional distribution, analyze the abnormal transmission values ​​in the stress concentration region; Based on the abnormal transmission value, query the partition compensation amount of the vulcanizing equipment in the molding production line; Based on the zoning compensation amount, the heating power of each temperature zone of the vulcanizing equipment is set; Based on the heating power, adjust the temperature setting of the vulcanizing equipment in the molding production line.

[0009] Optionally, the step of determining the slurry wetting interface corresponding to the target casing based on the initial production process includes: Analyze the set of process parameters in the initial production process; Based on the set of process parameters, extract the slurry formulation information corresponding to the target casing; Based on the slurry formulation information, analyze the rheological properties of the slurry in the initial production process; Based on the rheological performance indicators, the wetting conditions of the fiber surface corresponding to the target sleeve are identified; Based on the aforementioned wetting conditions, the slurry wetting interface corresponding to the target casing is determined.

[0010] Optionally, the step of analyzing the fiber-rubber composite structure corresponding to the target sleeve based on the real-time deformation state includes: Extract the deformation data from the real-time deformation state; Based on the deformation data, locate the fiber distribution area corresponding to the target sleeve; Scan the fiber orientation information in the fiber distribution area; Based on the fiber orientation information, determine the rubber filling state corresponding to the target sleeve; Based on the rubber filling state, the fiber-rubber composite structure corresponding to the target sleeve is analyzed.

[0011] Optionally, quantifying the heat accumulation effect value of the target sleeve in a vulcanization scenario based on the heat conduction characteristics includes: Based on the aforementioned thermal conduction characteristics, the thermal conductivity values ​​between the layers of the target sleeve are analyzed. Based on the thermal conductivity value, the heat flux index of the bonding layer under the vulcanization scenario is analyzed. Based on the heat flux index, the temperature distribution value of the target sleeve during the vulcanization process is determined; Based on the temperature distribution value, query the amount of heat accumulation in the target sleeve; Based on the amount of heat accumulation, the heat accumulation effect value of the target sleeve in the vulcanization scenario is quantified.

[0012] Optionally, calculating the thermal stress level of the target sleeve at each vulcanization stage based on the thermal accumulation effect value includes: Divide the target casing into independent vulcanization periods; Extract the time-period heat distribution within the independent vulcanization periods; Based on the heat distribution during the specified time period, analyze the interlayer temperature difference corresponding to the target casing; Based on the interlayer temperature difference, the difference in expansion between the rubber and the fiber in the target sleeve is determined; Based on the aforementioned expansion differences, the thermal stress level of the target casing at each vulcanization stage is calculated using the following formula.

[0013] in, This indicates the degree of thermal stress in the target casing at each vulcanization stage. This indicates the total number of vulcanization stages. Indicating the number of vulcanization stages, This indicates the total number of bonding layers corresponding to the target sleeve. Indicates the index of the number of layers. This represents the equivalent elastic modulus of the j-th bonding layer. This represents the difference in expansion between the rubber and the fiber at the j-th bonding layer during the i-th vulcanization stage.

[0014] Optionally, optimizing the pressure gradient value of the target sleeve in the preset impregnation pressure field based on the material effect term includes: Analyze the slurry rheological parameters in the material effect term; Based on the rheological parameters of the slurry, the current pressure in the preset impregnation pressure field is analyzed; Based on the current pressure conditions, the wetting uniformity of the target sleeve is detected; Based on the aforementioned wetting uniformity, the target pressure value of the preset impregnation pressure field is determined; Based on the target pressure value, the pressure gradient value of the target sleeve in the preset impregnation pressure field is optimized.

[0015] Optionally, optimizing the forming process parameters corresponding to the target sleeve based on the pressure gradient value includes: Based on the pressure gradient value, analyze the immersion pressure segment corresponding to the target casing; Based on the impregnation pressure range, the slurry flow state corresponding to the target casing is determined; Adjust the viscosity of the rubber matrix in the target sleeve according to the slurry flow state; Based on the adjusted rubber matrix viscosity, the vulcanization reaction conditions corresponding to the target sleeve are set. Based on the vulcanization reaction conditions, the mold temperature profile required to generate the target sleeve is as follows; Based on the mold temperature curve, the forming process parameters corresponding to the target sleeve are optimized.

[0016] To address the above problems, the present invention also provides a precision molding control system for silicone rubber glass fiber sleeves, the system comprising: The pattern analysis module is used to obtain the initial production process corresponding to the target casing, determine the slurry wetting interface corresponding to the target casing based on the initial production process, and analyze the rheological behavior pattern corresponding to the slurry wetting interface. The feature detection module is used to detect the real-time deformation state of the target sleeve in the preset molding production line based on the rheological behavior pattern, analyze the fiber-rubber composite structure of the target sleeve based on the real-time deformation state, and detect the thermal conductivity characteristics of each bonding layer in the fiber-rubber composite structure. The degree calculation module is used to quantify the heat accumulation effect value of the target sleeve in the vulcanization scenario based on the heat conduction characteristics, and to calculate the thermal stress degree value of the target sleeve in each vulcanization stage based on the heat accumulation effect value. The gradient value optimization module is used to determine the optimal crosslinking process of the target sleeve in the molding production line based on the thermal stress level value, detect the material effect term corresponding to the optimal crosslinking process, and optimize the pressure gradient value of the target sleeve in the preset impregnation pressure field based on the material effect term. The scheme formulation module is used to optimize the forming process parameters corresponding to the target sleeve based on the pressure gradient value, identify the optimized process elements in the optimized forming process parameters, and formulate a parameter control scheme for the target sleeve regarding forming precision based on the optimized process elements.

[0017] Compared to the problems described in the background art, this invention, by obtaining the initial production process corresponding to the target sleeve, can provide a precise benchmark for subsequent molding control, ensuring that process optimization has a clear starting point. It can directly identify the core basic conditions of production, reduce deviations caused by adjustments without a basis, and improve the targeting of control. Simultaneously, this step can anchor key production prerequisites in advance, helping to ensure the stability of product molding quality. Based on the rheological behavior pattern, this invention detects the real-time deformation state of the target sleeve in the preset molding production line, allowing the state perception during the molding process to closely match the actual dynamics, accurately capturing the core characteristics of morphological changes, and promptly identifying potential morphological anomalies. This avoids molding problems caused by the accumulation of deviations, ensuring the stability of the molding process. Furthermore, based on the heat conduction characteristics, this invention quantifies the heat accumulation effect value of the target sleeve in the vulcanization scenario, transforming the abstract heat accumulation state into a precisely quantifiable value. By controlling quantitative indicators and clearly understanding the cumulative pattern of heat distribution, this invention can promptly identify potential risks of excessive or uneven heat accumulation, avoiding product defects caused by thermal imbalance during vulcanization and ensuring the stability of the vulcanization stage. Furthermore, based on the aforementioned thermal stress level value, this invention determines the optimal crosslinking process for the target sleeve in the molding production line, enabling the crosslinking process to precisely adapt to the thermal stress distribution state, effectively avoiding structural defects caused by stress imbalance. It allows for targeted control of each stage of crosslinking, helping to solidify the quality foundation of the target sleeve's precision molding from the crosslinking stage. Finally, based on the aforementioned pressure gradient value, this invention optimizes the molding process parameters corresponding to the target sleeve, allowing the process parameters to accurately match the actual needs of impregnation and molding, strengthening the adaptability of parameters to material properties and pressure environment, effectively avoiding molding defects caused by parameter imbalance, and ensuring the stability and continuity of the entire molding process. Therefore, the precision molding control method and system for silicone rubber glass fiber sleeves provided by this invention can improve the molding accuracy and reliability of silicone rubber glass fiber sleeves. Attached Figure Description

[0018] Figure 1 This is a flowchart illustrating a precision molding control method for silicone rubber glass fiber sleeves according to an embodiment of the present invention. Figure 2This is a schematic diagram of a module for implementing a precision molding control system for silicone rubber glass fiber sleeves according to an embodiment of the present invention.

[0019] The objectives, features, and advantages of this invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0021] This application provides a method for precision molding control of silicone rubber glass fiber sleeves. The executing entity of this method includes, but is not limited to, at least one of the following electronic devices that can be configured to execute the method provided in this application: a server, a terminal, etc. In other words, the method for precision molding control of silicone rubber glass fiber sleeves can be executed by software or hardware installed on a terminal device or a server device. The server includes, but is not limited to, a single server, a server cluster, a cloud server, or a cloud server cluster.

[0022] Reference Figure 1 The diagram shown is a flowchart illustrating a precision molding control method for silicone rubber glass fiber sleeves according to an embodiment of the present invention. In this embodiment, the precision molding control method for silicone rubber glass fiber sleeves includes: S1. Obtain the initial production process corresponding to the target casing, determine the slurry wetting interface corresponding to the target casing based on the initial production process, and analyze the rheological behavior mode corresponding to the slurry wetting interface.

[0023] This invention, by obtaining the initial production process corresponding to the target sleeve, can provide a precise benchmark for subsequent forming control, ensuring that process optimization has a clear starting point. It can directly identify the core basic conditions of production, reduce deviations caused by adjustments without a basis, and improve the targeting of control. At the same time, this step can anchor the key production prerequisites in advance, helping to ensure the stability of product forming quality.

[0024] The target sleeve refers to a silicone rubber and glass fiber sleeve with specific insulation protection functions and application scenario requirements, which is to be precisely manufactured using this molding control method and system. This includes preset inner diameter, wall thickness range, withstand voltage rating, and mechanical strength standards, adapting to the protection needs of wires and cables in harsh environments such as high temperature and high humidity. The initial production process refers to a pre-set basic production technology scheme based on the target sleeve's material formula, design requirements, and existing production experience. It covers core control items such as the speed and pressure of the impregnation process, the temperature and time of the vulcanization stage, and the density of fiber weaving. It is an initial execution scheme derived by combining production data and material characteristics of similar products. Optionally, obtaining the initial production process corresponding to the target sleeve can be achieved through a database query method, such as accessing the historical process database in the manufacturing execution system to retrieve standardized production process records for sleeves of the same specifications, thereby obtaining the initial production process.

[0025] Furthermore, based on the initial production process, the present invention determines the slurry wetting interface corresponding to the target sleeve, which can clearly define the core contact area between the slurry and the fiber, providing a clear target for key interactive control in the molding process. At the same time, it can lock in the core links that affect the molding quality in advance, helping to improve the stability and accuracy of product molding.

[0026] The slurry wetting interface refers to the dynamic bonding area formed after the slurry and fiber surface come into contact and undergo physical adsorption and chemical reaction during the molding process. It clarifies the coverage area, bonding depth and interface morphology of the slurry on the fiber surface. It is the core area for the effective wetting of the slurry and fiber and defines the boundary and state of their interaction.

[0027] As an embodiment of the present invention, determining the slurry wetting interface corresponding to the target sleeve based on the initial production process includes: parsing the process parameter set in the initial production process; extracting the slurry formulation information corresponding to the target sleeve based on the process parameter set; analyzing the rheological performance indicators corresponding to the slurry in the initial production process based on the slurry formulation information; identifying the wetting conditions of the fiber surface corresponding to the target sleeve based on the rheological performance indicators; and determining the slurry wetting interface corresponding to the target sleeve based on the wetting conditions.

[0028] The process parameter set refers to the set of all specific technical parameters related to the forming of the target sleeve included in the initial production process. It covers the control indicators of all key stages in the entire forming process, including not only the operational parameters of core processes such as impregnation, vulcanization, and fiber weaving, but also the set values ​​of auxiliary stages such as material handling and environmental control. The slurry formulation information refers to the core technical information that clarifies the types, proportions, and related modulation standards of each component in the slurry based on the performance requirements of the target sleeve. This includes the type of silicone rubber matrix material, the ratio of glass fiber reinforcement, and the dosage and mixing method of functional additives such as crosslinking agents and flame retardants. The rheological performance indicators describe the properties of the slurry under stress or temperature. The key technical parameters governing the flow and deformation behavior under varying conditions mainly include the viscosity, shear rate, elastic modulus, and yield stress of the slurry. The fiber surface refers to the surface layer of the glass fiber braided structure in the target sleeve, encompassing key characteristics such as the fiber's surface morphology, chemical properties, and physical state, including attributes such as surface roughness, pore distribution, functional group type, and surface cleanliness. The wetting conditions refer to various technical requirements and environmental parameters that ensure effective contact, uniform spreading, and stable bonding between the slurry and the fiber surface, including key factors such as the temperature range, contact time, relative motion state, and initial state of the slurry.

[0029] Furthermore, the process parameter set in the initial production process can be parsed using a file parsing algorithm, such as using an XML parser to extract impregnation rate, vulcanization temperature, and time parameters from the process file to obtain the process parameter set; the extraction of the slurry formulation information corresponding to the target sleeve can be achieved through a product data management system, such as querying the material list module of the PDM system to obtain the weight percentage data of silicone rubber and curing agent to obtain the slurry formulation information; the analysis of the rheological performance indicators corresponding to the slurry in the initial production process can be achieved through a rotational rheometer testing method, such as: Dynamic oscillation tests were performed using a Hacker rotational rheometer to obtain storage modulus and loss modulus curves, thereby obtaining rheological performance indicators. The identification of the wetting conditions of the fiber surface corresponding to the target sleeve can be achieved through contact angle measurement technology, such as using a pendant drop contact angle meter to measure the static contact angle between the fiber surface and the slurry, thereby obtaining the wetting conditions. The determination of the slurry wetting interface corresponding to the target sleeve can be achieved through scanning electron microscopy observation methods, such as using field emission scanning electron microscopy to analyze the microstructure of the slurry and fiber cross sections, identify the thickness of the interface bonding layer, thereby obtaining the slurry wetting interface.

[0030] This invention analyzes the rheological behavior patterns corresponding to the slurry wetting interface, which can accurately capture the dynamic flow and deformation laws of the slurry at the interface, clarify its interaction with the fiber, and provide key behavioral basis for molding control, thus helping to improve the accuracy of process control.

[0031] The rheological behavior mode refers to the regular characteristics of dynamic flow, deformation and stress response of the slurry at the slurry wetting interface under the combined influence of process conditions and fiber surface characteristics. It covers the changes in flow rate, viscosity adaptation law, shear deformation trend and elastic recovery characteristics of the slurry in the interface region. Optionally, the analysis of the rheological behavior mode corresponding to the slurry wetting interface can be realized by computational fluid dynamics simulation method, such as using COMSOL software to perform two-phase flow simulation to simulate the shear thinning behavior of the slurry at the interface, thereby obtaining the rheological behavior mode.

[0032] S2. Based on the rheological behavior pattern, detect the real-time deformation state of the target sleeve in the preset molding production line, analyze the fiber-rubber composite structure corresponding to the target sleeve based on the real-time deformation state, and detect the thermal conductivity characteristics of each bonding layer in the fiber-rubber composite structure.

[0033] Based on the rheological behavior pattern, this invention detects the real-time deformation state of the target sleeve in a preset molding production line, enabling the state perception during the molding process to closely match the actual dynamics, accurately capture the core features of morphological changes, promptly identify potential morphological anomalies, avoid molding problems caused by the accumulation of deviations, and ensure the stability of the molding process.

[0034] The pre-formed production line refers to a complete production system specifically built to achieve precision forming of the target sleeve, integrating all equipment and processes from fiber weaving and slurry impregnation to vulcanization and cross-linking, and finished product shaping. The real-time deformation state refers to the changes in the shape and structure of the target sleeve during the production process of the pre-formed production line, as the process progresses, such as impregnation and vulcanization. It covers the dynamic characteristics of the sleeve, such as size fluctuations, shape deviations, and structural deformations, including wall thickness changes, cross-sectional shape shifts, and overall warping or shrinkage. Optionally, the detection of the real-time deformation state of the target sleeve in the pre-formed production line can be achieved by laser scanning measurement methods, such as using a laser displacement sensor array to scan the outer contour of the sleeve online and obtain three-dimensional point cloud data to obtain the real-time deformation state.

[0035] Furthermore, based on the real-time deformation state, the present invention analyzes the fiber-rubber composite structure corresponding to the target sleeve, which allows the structural analysis to closely follow the molding dynamic process, accurately capture the core components and bonding state of the composite structure, and promptly identify potential anomalies at the structural level, avoiding the impact of accumulated structural defects on the core performance of the product and ensuring the stability of the composite structure.

[0036] The fiber-rubber composite structure refers to the integrated synergistic structure formed by glass fiber and silicone rubber in the target sleeve through a molding process. It is the core carrier for the sleeve to achieve insulation protection and mechanical support functions. It integrates the high-strength support characteristics of fiber and the flexible insulation characteristics of rubber, including the spatial skeleton layout of fiber, the filling and bonding state of rubber and the bonding form of the interface between the two.

[0037] As an embodiment of the present invention, the step of analyzing the fiber-rubber composite structure corresponding to the target sleeve based on the real-time deformation state includes: extracting deformation data from the real-time deformation state; locating the fiber distribution area corresponding to the target sleeve based on the deformation data; scanning the fiber orientation information in the fiber distribution area; determining the rubber filling state corresponding to the target sleeve based on the fiber orientation information; and analyzing the fiber-rubber composite structure corresponding to the target sleeve based on the rubber filling state.

[0038] The deformation data refers to a set of specific data extracted from the real-time deformation state of the target sleeve, which can quantify morphological and structural changes. It covers key quantitative indicators such as dimensional fluctuations, shape shifts, and structural deformation during the sleeve's forming process. This includes both macroscopic overall morphological changes and microscopic local structural deformation information. These data accurately record the dynamic trajectory of the sleeve as the process progresses. The fiber distribution area refers to the spatial distribution range and concentrated area of ​​the glass fiber braided portion in the target sleeve, precisely located based on the deformation data. It clarifies the spatial location, distribution density, and extension range of the fibers inside the sleeve, reflecting the layout characteristics of the fibers as a reinforcing phase. This area is the main site of interaction between fibers and rubber, and its definition provides a clear spatial target for scanning fiber orientation and determining the rubber filling state. The fiber orientation information refers to the information obtained by analyzing the fiber distribution data. The key information obtained from the area scanning, reflecting the arrangement of glass fibers, includes core content such as fiber arrangement direction, distribution angle, orientation consistency, and extension trend, clearly showing the spatial arrangement pattern of fibers within the distribution area. The rubber filling state refers to the filling status of silicone rubber slurry in the fiber gaps within the fiber distribution area, determined based on fiber orientation information. It encompasses key characteristics such as the degree of rubber filling, filling uniformity, tightness of adhesion to the fiber surface, and the presence of filling gaps, directly reflecting the initial bonding effect between rubber and fiber. The fiber-rubber composite structure refers to the integrated synergistic structure formed by glass fiber and silicone rubber in the target sleeve through a molding process. It is the core carrier for the sleeve to achieve insulation protection and mechanical support functions. It integrates the high-strength support characteristics of fiber and the flexible insulation characteristics of rubber, including the spatial skeleton layout of fiber, the filling and bonding state of rubber, and the bonding morphology of the interface between the two.

[0039] Furthermore, the extraction of deformation data from the real-time deformation state can be achieved through point cloud data processing algorithms, such as: using the least squares method to fit the three-dimensional point cloud data to a surface, calculating the deviation from the standard model, thereby obtaining the deformation data; the location of the fiber distribution area corresponding to the target sleeve can be achieved through micro-focus X-ray imaging methods, such as: using an X-ray computed tomography system to perform non-destructive scanning of the sleeve sample, reconstructing the internal structure image, thereby obtaining the fiber distribution area; the scanning of fiber orientation information in the fiber distribution area can be achieved through image analysis algorithms, such as: using the orientation analysis module of ImageJ software to process the scanned image, calculating the principal orientation angle of the fibers, thereby obtaining the fiber orientation information; the determination of the rubber filling state corresponding to the target sleeve can be achieved through ultrasonic detection methods, such as: using an ultrasonic flaw detector to emit longitudinal waves and receive echo signals, evaluating the compactness of the rubber filling through the signal attenuation degree, thereby obtaining the rubber filling state; the analysis of the fiber-rubber composite structure corresponding to the target sleeve can be achieved through finite element modeling methods, such as: establishing a representative volume element model in Abaqus software based on fiber distribution and rubber filling data, thereby obtaining the fiber-rubber composite structure.

[0040] This invention, by detecting the thermal conductivity characteristics of each bonding layer in the fiber-rubber composite structure, can accurately capture the heat transfer patterns of different bonding layers, clarify the core state of heat distribution, promptly detect abnormal heat conduction, avoid structural defects caused by uneven heat distribution, and ensure the stability of the composite structure.

[0041] The thermal conductivity characteristics refer to the inherent properties and changing patterns of each bonding layer in the fiber-rubber composite structure during heat transfer. They are a set of core indicators reflecting the heat transfer capacity and state of the bonding layers, encompassing key aspects such as the thermal conductivity, thermal diffusion rate, thermal resistance distribution, and temperature conduction uniformity of each bonding layer. Optionally, the detection of the thermal conductivity characteristics of each bonding layer in the fiber-rubber composite structure can be achieved by the transient planar heat source method, such as using a Hot Disk thermal constant analyzer to measure the thermal conductivity and thermal diffusion coefficient at the interface, thereby obtaining the thermal conductivity characteristics.

[0042] S3. Based on the heat conduction characteristics, quantify the heat accumulation effect value of the target sleeve in the vulcanization scenario, and calculate the thermal stress level value of the target sleeve in each vulcanization stage based on the heat accumulation effect value.

[0043] Based on the aforementioned thermal conduction characteristics, this invention quantifies the thermal accumulation effect value of the target sleeve in a vulcanization scenario. It can transform the abstract thermal accumulation state into a precisely controllable quantitative indicator, clearly grasp the accumulation law of heat distribution, and promptly identify potential risks of excessive or uneven heat accumulation, thereby avoiding product defects caused by thermal imbalance during the vulcanization process and ensuring the stability of the vulcanization stage.

[0044] The vulcanization scenario refers to the specific process environment and execution conditions set during the molding process of the target sleeve to achieve cross-linking and curing of silicone rubber and fiber and form a stable composite structure. It includes the temperature range, heat preservation time, environmental atmosphere and process progress rhythm of the vulcanization stage. The heat accumulation effect value refers to the final index obtained by quantifying the degree of heat accumulation of the target sleeve under the vulcanization scenario, taking heat accumulation as the core and comprehensively considering factors such as heat conduction characteristics and temperature distribution.

[0045] As an embodiment of the present invention, the step of quantifying the heat accumulation effect value of the target sleeve in a vulcanization scenario based on the heat conduction characteristics includes: analyzing the thermal conductivity values ​​between the layers of the target sleeve based on the heat conduction characteristics; analyzing the heat flow index of the bonding layer in a vulcanization scenario based on the thermal conductivity values; determining the temperature distribution value of the target sleeve during the vulcanization process based on the heat flow index; querying the amount of heat accumulation in the target sleeve based on the temperature distribution value; and quantifying the heat accumulation effect value of the target sleeve in a vulcanization scenario based on the amount of heat accumulation.

[0046] The thermal conductivity value refers to the quantitative indicator of the ability of each bonding layer and the material itself of the target sleeve to transfer heat per unit area per unit time during the heat transfer process. Its value is related to the material composition, the tightness of the bonding layers and the microstructure, and can accurately reflect the efficiency of heat transfer between different layers. The heat flow index is a quantitative indicator derived from the thermal conductivity values ​​of each layer, reflecting the intensity, direction and trend of heat flow between the bonding layers of the target sleeve under the vulcanization scenario. The temperature distribution value refers to the specific temperature data set of each part and bonding layer of the target sleeve at different time points obtained by heat flow index analysis during the vulcanization process. It covers the temperature difference between the surface and the inside of the sleeve, the temperature gradient of different areas and the temperature change with the progress of the process, and comprehensively reflects the spatial distribution of heat in the sleeve. The heat accumulation amount refers to the total amount of heat accumulated in each part and the whole of the target sleeve during a specific time period during the vulcanization process, which is obtained by querying the temperature distribution value.

[0047] Furthermore, the analysis of the thermal conductivity values ​​between the layers of the target sleeve can be achieved using the laser flash method, such as by using a Netzsch laser thermal conductivity meter to measure the thermal diffusivity of the rubber layer and fiber layer and calculating the specific heat capacity to obtain the thermal conductivity value; the analysis of the heat flux index of the bonding layer under vulcanization conditions can be achieved using computational fluid dynamics and heat transfer coupled simulation methods, such as using ANSYS. Fluent software simulates the heat flux density at the interface under vulcanization hot-pressing conditions to obtain the heat flux index. The temperature distribution value of the target sleeve during the vulcanization process can be determined using an embedded thermocouple temperature measurement method, such as pre-embedding a K-type thermocouple sensor array inside the sleeve blank and recording the temperature time-series data during the vulcanization process to obtain the temperature distribution value. The amount of heat accumulation in the target sleeve can be queried using thermal imaging analysis technology, such as using a FLIR infrared thermal imager to capture the surface temperature field of the vulcanized sleeve and integrating the total heat to obtain the heat accumulation amount. The quantification of the heat accumulation effect value of the target sleeve under the vulcanization scenario can be achieved using a thermal load integration algorithm, such as integrating the temperature distribution value over time and multiplying it by the material's equivalent heat capacity to calculate the overall heat absorption, thereby obtaining the heat accumulation effect value.

[0048] Based on the aforementioned heat accumulation effect value, this invention calculates the degree of thermal stress of the target sleeve at each vulcanization stage, which can transform the stress state caused by heat accumulation into a precise quantitative indicator, clearly grasp the stress change law at different stages, promptly detect potential problems such as excessive stress or uneven distribution, avoid structural defects caused by heat stress accumulation, and ensure the stability of the vulcanization process.

[0049] The thermal stress level value refers to the index obtained by quantifying the magnitude, distribution and influence of internal stress caused by thermal effects in each vulcanization stage of the target sleeve, which is based on the interlayer temperature difference, expansion difference between rubber and fiber, and the mechanical properties of the material itself, taking into account the temperature difference between the layers during independent vulcanization periods. It transforms the abstract stress state caused by material deformation incoordination into a quantifiable specific value, and can intuitively reflect the severity of thermal stress in each vulcanization stage.

[0050] As an embodiment of the present invention, the step of calculating the thermal stress level of the target sleeve at each vulcanization stage based on the heat accumulation effect value includes: dividing the target sleeve into independent vulcanization periods; extracting the heat distribution of the independent vulcanization periods; analyzing the interlayer temperature difference of the target sleeve based on the heat distribution of the periods; determining the expansion difference between the rubber and the fiber in the target sleeve based on the interlayer temperature difference; and calculating the thermal stress level of the target sleeve at each vulcanization stage by combining the expansion difference.

[0051] The independent vulcanization period refers to a stable process execution stage in the vulcanization process, with clear start and end points and specific process control targets, based on the temperature change pattern, crosslinking reaction progress, and process control nodes of the target casing vulcanization process. The heat distribution of the period refers to the heat distribution state and quantitative data set of each part and bonding layer of the target casing within each independent vulcanization period, which covers the heat ratio, heat concentration, and distribution uniformity between the casing surface and interior, and between different bonding layers within that period. The interlayer temperature difference refers to the temperature difference between different bonding layers in the fiber-rubber composite structure of the target casing, derived from the heat distribution analysis of the independent vulcanization period. It reflects the temperature difference of each bonding layer within a specific vulcanization period, directly stemming from the difference in heat conduction efficiency and heat accumulation of each layer, and is a key factor causing the difference in expansion between rubber and fiber. The expansion difference refers to the quantitative difference in the degree of expansion or contraction of the rubber material and glass fiber in the target casing under the same vulcanization conditions due to their different coefficients of thermal expansion affected by the interlayer temperature difference of the independent vulcanization period.

[0052] Furthermore, the division of the independent vulcanization periods corresponding to the target sleeve can be achieved through vulcanization reaction kinetic analysis methods, such as: dividing the induction period, scorching period, and positive vulcanization period according to the vulcanization exothermic curve measured by differential scanning calorimetry, thereby obtaining independent vulcanization periods; the extraction of the heat distribution of the independent vulcanization periods can be achieved through the time-temperature equivalent superposition method, such as: performing numerical integration on the thermocouple temperature measurement data in each period to obtain the heat absorbed in that period, thereby obtaining the heat distribution of the period; the analysis of the interlayer temperature difference corresponding to the target sleeve can be achieved through the range statistical algorithm, such as: calculating the difference between the maximum and minimum values ​​of the thermocouple temperature measurement data at different depths at the same time point, thereby obtaining the interlayer temperature difference; the determination of the expansion difference between rubber and fiber in the target sleeve can be achieved through thermomechanical analysis, such as: using a thermomechanical analyzer to test the linear thermal expansion coefficients of the two materials in the vulcanization temperature range and calculating the difference, thereby obtaining the expansion difference; the calculation of the thermal stress level of the target sleeve in each vulcanization stage can be achieved through the thermo-structural coupled finite element analysis method, such as: in ANSYS In Mechanical, the temperature field is applied as a load to the structural model for stress simulation, and the von Mises stress peak is extracted to obtain the thermal stress level value.

[0053] For example, the thermal stress level of the target sleeve at each vulcanization stage is calculated using the following formula. It should be noted that this calculation method is only one possible method and does not affect the implementation of the basic scheme above:

[0054] in, This indicates the degree of thermal stress in the target casing at each vulcanization stage. This indicates the total number of vulcanization stages. Indicating the number of vulcanization stages, This indicates the total number of bonding layers corresponding to the target sleeve. Indicates the index of the number of layers. This represents the equivalent elastic modulus of the j-th bonding layer. This represents the difference in expansion between the rubber and the fiber at the j-th bonding layer during the i-th vulcanization stage.

[0055] Furthermore, the thermal stress level value can represent a comprehensive index of the thermal stress of the target casing at each vulcanization stage. It comprehensively considers the synergistic effect of the elastic modulus and expansion difference of all vulcanization stages and all bonding layers, and intuitively reflects the overall severity of thermal stress. For example, a casing has 3 vulcanization stages (N=3) and 4 bonding layers (M=4), and the equivalent elastic modulus of each bonding layer... =1.2GPa =1.5GPa =1.3GPa =1.4 GPa, the difference in expansion between layers in stage 1 =0.002、 =0.003、 =0.0025、 =0.0035, Phase 2 =0.0022、 =0.0028、 =0.0026、 =0.0032, Stage 3 =0.0018、 =0.0025、 =0.0023、 =0.003, substituting into the formula allows for precise calculation of SL, used to determine whether the thermal stress during the vulcanization process of the sleeve exceeds a reasonable range; the vulcanization stage can represent the total number of stages representing the vulcanization process, reflecting the degree of segmentation and refinement of the vulcanization process; i is the index of the number of vulcanization stages (values ​​from 1 to N), used to distinguish different vulcanization sub-processes. For example, for silicone rubber glass fiber sleeves, vulcanization can be divided into a preheating stage (i=1), a main vulcanization stage (i=2), and a post-vulcanization stage (i=3), i.e. (N=3). The temperature, time, and other process parameters of each stage are different, and the generation mechanism and intensity of thermal stress vary. Through the i index, the contribution of each stage to the total thermal stress can be analyzed separately, achieving precise segmentation and control of the vulcanization process; the equivalent elastic modulus can represent the equivalent elastic modulus of the j-th bonding layer, reflecting the ability of the bonding layer material to resist elastic deformation, which is a key mechanical parameter when calculating thermal stress. For example, the target sleeve contains three bonding layers (M=3): fiber layer (j=1), rubber-fiber interface layer, and rubber matrix layer: fiber layer (j=1) The rubber-fiber interface layer (j=2) is equivalent to the interfacial effect. =5GPa, rubber matrix layer (j=3) =2GPa, these values ​​are determined by combining the material's inherent properties and the interface bonding state; the expansion difference can represent the expansion difference between the rubber and fiber at the j-th bonding layer in the i-th vulcanization stage, the degree of deformation incoordination caused by the difference in the thermal expansion coefficients of the rubber and fiber due to the interlayer temperature difference, for example, in the second vulcanization stage (i=2), the third bonding layer (j=3), the interface between the rubber matrix layer and the fiber layer), the rubber thermal expansion coefficient / ℃, coefficient of thermal expansion of fiber / ℃, interlayer temperature difference at this stage When T = 50℃, then This value directly reflects the degree of deformation incoordination caused by the difference in thermal expansion in this layer at this stage. It is the direct cause of thermal stress, and its magnitude is closely related to the thermal expansion characteristics of the material and the temperature difference between layers.

[0056] S4. Based on the thermal stress level value, determine the optimal crosslinking process of the target sleeve in the molding production line, detect the material effect term corresponding to the optimal crosslinking process, and optimize the pressure gradient value of the target sleeve in the preset impregnation pressure field based on the material effect term.

[0057] Based on the thermal stress level value, this invention determines the optimal crosslinking process for the target sleeve in the molding production line, enabling the crosslinking process to accurately adapt to the thermal stress distribution state, effectively avoiding structural defects caused by stress imbalance, and achieving targeted control of each stage of crosslinking, thus helping to solidify the quality foundation of the precision molding of the target sleeve from the crosslinking stage.

[0058] The optimal crosslinking process refers to the integrated and adjusted temperature setting and vulcanization time, taking into account the distribution of thermal stress, product performance requirements and production line efficiency. This process can control thermal stress within a reasonable range, ensuring the structural integrity and performance consistency of the product.

[0059] As an embodiment of the present invention, determining the optimal crosslinking process of the target sleeve in the molding production line based on the thermal stress level value includes: analyzing the thermal stress distribution of each vulcanization stage according to the thermal stress level value; querying the stress concentration area of ​​the current crosslinking process according to the thermal stress distribution; adjusting the temperature setting corresponding to the vulcanization equipment in the molding production line for the stress concentration area; reallocating the vulcanization time of each vulcanization stage according to the adjusted temperature setting; and integrating the temperature setting and the vulcanization time to determine the optimal crosslinking process of the target sleeve in the molding production line.

[0060] The thermal stress distribution refers to the state presented after a comprehensive analysis of the magnitude, location, and variation law of thermal stress in each vulcanization stage and bonding layer of the target sleeve based on the thermal stress level value, encompassing the spatial and temporal distribution characteristics of stress; the current crosslinking process refers to the existing complete process scheme for vulcanization crosslinking of the target sleeve in the molding production line, including the temperature parameters, time allocation, equipment operation logic, and process connection methods for each vulcanization stage, which is an execution standard set based on the initial process or past production experience; the stress concentration area refers to a local location or vulcanization stage in the thermal stress distribution where the thermal stress value is significantly higher than the surrounding area, and this area is a high-risk point for thermal stress to cause product structural defects; the sulfur The vulcanization equipment refers to specialized equipment in the molding production line specifically designed for achieving cross-linking and vulcanization of the target sleeve, encompassing components such as heating devices, temperature control systems, and conveying mechanisms. The temperature setting refers to the target temperature and temperature change control curve of each temperature zone in the vulcanization equipment, ultimately determined based on the zonal compensation amount and heating power. It optimizes the thermal environment defects in stress concentration areas and clarifies the temperature benchmark for each temperature zone during the vulcanization process. The vulcanization time refers to the duration during which the target sleeve is in the corresponding temperature environment in each vulcanization stage. Its duration setting affects the degree of cross-linking reaction and heat accumulation effect, and works synergistically with the temperature setting to influence the thermal stress state. By redistributing the vulcanization time for each stage, the thermal stress in each stage can be made more reasonable.

[0061] Furthermore, the analysis of the thermal stress distribution at each vulcanization stage can be achieved using a thermal-structural sequential coupling analysis method, such as in ANSYS. The Workbench platform maps the temperature field results obtained from transient thermal analysis to the structural field for stress calculation, thereby obtaining the thermal stress distribution. The query for stress concentration regions in the current crosslinking process can be achieved using extreme value statistical algorithms, such as performing peak search on the von Mises stress field in the finite element analysis results to identify regions where the stress exceeds the material's yield strength, thus obtaining the stress concentration regions. Adjusting the temperature setting of the vulcanizing equipment in the molding production line can be achieved using PID control algorithms, such as using proportional-integral-differential operations to output temperature correction commands to the vulcanizing furnace temperature control table based on the deviation between the thermal stress distribution and the target value, thus obtaining the temperature setting. The redistribution of vulcanization time for each vulcanization stage can be achieved using the vulcanization effect equivalence method, such as calculating the time required to achieve the same vulcanization effect at different temperatures based on the Arrhenius equation and redistributing it, thus obtaining the vulcanization time. Determining the optimal crosslinking process for the target sleeve in the molding production line can be achieved using multi-objective optimization algorithms, such as using a non-dominated sorting genetic algorithm to solve for the Pareto optimal solution set with the objective of minimizing thermal stress and vulcanization time, thus obtaining the optimal crosslinking process.

[0062] In detail, as another embodiment of the present invention, adjusting the temperature setting of the vulcanizing equipment in the molding production line for the stress concentration area includes: analyzing the regional distribution details corresponding to the stress concentration area; analyzing the abnormal conduction value in the stress concentration area based on the regional distribution details; querying the zone compensation amount of the vulcanizing equipment in the molding production line based on the abnormal conduction value; setting the heating power of each temperature zone of the vulcanizing equipment according to the zone compensation amount; and adjusting the temperature setting of the vulcanizing equipment in the molding production line based on the heating power.

[0063] The detailed regional distribution refers to a comprehensive description of the spatial location of the stress concentration area, the structure of the bonding layers involved, and the vulcanization stage, clearly showing the specific distribution pattern and range of stress concentration. It includes the three-dimensional location of the area in the target sleeve, the number of bonding layers covered, and the degree of participation of each layer. The abnormal conduction value refers to a quantitative indicator of the thermal conductivity deviating from the normal reasonable range within the stress concentration area, reflecting the degree of abnormality in the heat transfer efficiency and thermal resistance characteristics of the area. It originates from differences in material properties, structural defects, or imbalances in process parameters. The zone compensation amount refers to the temperature compensation value calculated for different temperature zones of the vulcanization equipment based on the abnormal conduction value. It is used to correct the original temperature setting of the temperature zone to balance the thermal environment of the stress concentration area. The heating power refers to the energy output value required by each temperature zone of the vulcanization equipment to reach the adjusted target temperature. It directly determines the heating intensity and temperature rise rate of the temperature zone. It is determined according to the zone compensation amount. By adjusting the heating power of different temperature zones, local temperature compensation of the stress concentration area can be achieved.

[0064] Furthermore, the analysis of the regional distribution details corresponding to the stress concentration region can be achieved through finite element post-processing techniques, such as extracting the coordinate positions, stress values, and gradient information of stress concentration elements in HyperMesh software to generate a report, thereby obtaining the regional distribution details; the analysis of abnormal conduction values ​​in the stress concentration region can be achieved through thermal resistance network calculation methods, such as constructing a detailed thermal network model of the bonding layer and calculating the heat flux density ratio between the abnormal region and the normal region, thereby obtaining the abnormal conduction value; the query of the zonal compensation amount of the vulcanizing equipment in the molding production line can be achieved through equipment parameter library retrieval methods, such as from PLC control. The system reads the preset temperature offset data of each independent temperature zone to compensate for heat loss, thereby obtaining the zone compensation amount; the setting of the heating power of each temperature zone of the vulcanizing equipment can be achieved by fuzzy control method, such as: according to the difference between the target temperature and the measured temperature and the rate of change of the difference, the output of the thyristor power regulator is dynamically adjusted by applying the fuzzy inference rule table, thereby obtaining the heating power; the adjustment of the temperature setting of the vulcanizing equipment in the molding production line can be achieved by model predictive control method, such as: establishing a dynamic temperature model of the vulcanizing furnace, and continuously optimizing the current temperature setting value with the goal of minimizing the error between the predicted output and the set trajectory in the next few steps, thereby obtaining the temperature setting.

[0065] This invention can accurately control the impact of the process on material properties by detecting the material effect terms corresponding to the optimal crosslinking process, ensuring that the material properties meet the design requirements, timely identifying material performance deviations caused by the process, avoiding product defects caused by abnormal material effects, and verifying the actual effectiveness of the optimal crosslinking process.

[0066] The material effect term refers to the set of various changes and related quantitative indicators of the material in terms of physical state, chemical properties and mechanical properties after the optimal crosslinking process is applied to the target sleeve material. It covers key parameters such as the crosslinking density, functional group reaction degree, elastic recovery ability and mechanical strength stability of the material, and directly reflects the modification effect and law of the crosslinking process on the material. Optionally, the detection of the material effect term corresponding to the optimal crosslinking process can be achieved by dynamic mechanical analysis method, such as: using a DMA tester to measure the change of the peak value of the loss factor tanδ of the sleeve sample after crosslinking, and evaluating the degree of vulcanization, thereby obtaining the material effect term.

[0067] Furthermore, based on the aforementioned material effect term, the present invention optimizes the pressure gradient value of the target sleeve in a preset impregnation pressure field, enabling precise pressure control to match the actual performance state of the material, enhancing the matching degree between pressure distribution and material properties, effectively avoiding problems such as uneven impregnation caused by improper pressure gradient, helping to improve the structural integrity of the target sleeve, and further consolidating the quality foundation of precision forming.

[0068] The preset impregnation pressure field refers to the pressure environment system pre-constructed in the molding production line to achieve the target sleeve slurry impregnation process. It includes the pressure distribution range, intensity level, direction of action, and dynamic change law. It is set according to the initial process requirements and basic material properties, providing the necessary pressure support for the slurry to penetrate the fiber gaps and form a uniform bond. It is the core environmental carrier for the effective wetting of slurry and fiber. The pressure gradient value refers to the pressure change rate between different locations in the impregnation pressure field, reflecting the spatial distribution gradient and transmission law of pressure. Its value and change trend directly affect the penetration rate and filling uniformity of slurry in the fiber gaps. By optimizing this value, the pressure field distribution can be made more in line with the rheological properties of slurry and the requirements of material effect.

[0069] As an embodiment of the present invention, optimizing the pressure gradient value of the target sleeve in a preset impregnation pressure field based on the material effect term includes: analyzing the slurry rheological parameters in the material effect term; analyzing the current pressure condition in the preset impregnation pressure field based on the slurry rheological parameters; detecting the wetting uniformity corresponding to the target sleeve based on the current pressure condition; determining the target pressure value of the preset impregnation pressure field based on the wetting uniformity; and optimizing the pressure gradient value of the target sleeve in the preset impregnation pressure field based on the target pressure value.

[0070] The slurry rheological parameters refer to the core quantitative indicators reflecting the flow and deformation characteristics of the slurry in the material effect terms, covering key parameters such as viscosity, shear rate, elastic modulus, and yield stress. The current pressure condition refers to the actual pressure distribution state and quantitative data in the preset impregnation pressure field, derived from the analysis of the slurry rheological parameters, which includes the specific pressure value, pressure differences in different regions, pressure transmission efficiency, and stability. The wetting uniformity refers to the uniformity of filling, covering, and bonding of the slurry in the fiber distribution area of ​​the target sleeve, obtained through detection. It includes the consistency of the penetration depth of the slurry in the fiber gaps, the integrity of the surface coverage, and the tightness of the bonding in each region. The target pressure value refers to the standard value of the impregnation pressure field that enables the slurry to achieve uniform wetting, determined based on the wetting uniformity detection results and combined with the requirements of the slurry rheological parameters and material effect terms. It comprehensively considers the slurry flow characteristics, fiber distribution characteristics, and wetting quality requirements.

[0071] Furthermore, the analysis of the slurry rheological parameters in the material effect term can be achieved through capillary rheometer testing methods, such as using a Gautford capillary rheometer to measure the relationship between the apparent viscosity and shear stress of the slurry at a specific shear rate to obtain the slurry rheological parameters; the analysis of the current pressure in the preset impregnation pressure field can be achieved through pressure sensor array monitoring methods, such as using pressure transmitters installed at multiple locations on the impregnation tank to collect and upload pressure data to the SCADA system in real time to obtain the current pressure; the detection of the wetting uniformity corresponding to the target sleeve can be achieved through calculation. The impregnation uniformity can be obtained by using computed tomography (CT) imaging methods, such as performing micron-level CT scans on the molded sleeve sample and calculating the variance of the filling ratio of the slurry in the fiber bundle using image grayscale analysis software. The target pressure value of the preset impregnation pressure field can be determined through response surface optimization methods, such as using impregnation uniformity as the response variable, designing an experiment to construct a second-order model of pressure and uniformity, and finding its optimal solution. The pressure gradient value of the target sleeve in the preset impregnation pressure field can be optimized through computational fluid dynamics optimization methods, such as parametrically modeling the impregnation process in ANSYS CFX software, using the gradient descent method to iteratively calculate the pressure change curve that maximizes impregnation uniformity, thereby obtaining the pressure gradient value.

[0072] In detail, the pressure gradient value can be calculated using the following formula:

[0073] in, This represents the pressure gradient value (MPa / m). Indicates the target pressure value (MPa). This indicates the initial pressure value (MPa). This indicates the length of the impregnation path (m), which can be monitored in real time to ensure uniformity of impregnation. Iterative optimization using response surface methodology This optimizes the penetration rate and filling uniformity of the slurry in the fiber gaps.

[0074] Optionally, a single type of silicone rubber glass fiber sleeve was selected as the experimental object, and its basic parameters are as follows:

[0075] Furthermore, the experimental steps included: 1. Rheological behavior analysis: A rotational rheometer was used at shear rates of 0.1~100 The viscosity of the slurry was tested within a certain range, and the Carreau model parameters were obtained by fitting: zero shear viscosity η0 = 850 Pa. 1. Relaxation time λ=0.12s, power law exponent n=0.68; 2. Real-time deformation detection: During impregnation and vulcanization, the array of laser displacement sensors is used to scan the change in the outer diameter of the sleeve online, with a sampling frequency of 50 Hz, to locate the fiber distribution area and the peak deformation position; 3. Quantification of thermal accumulation effect: Based on transient heat conduction finite element simulation, the thermal conductivity of each layer is input (rubber layer 0.25W / m). K, fiber layer 0.45W / m K, interface layer 0.32 W / m K), the heat accumulation effect value is calculated. =2.34×10⁵ .

[0076] S5. Based on the pressure gradient value, optimize the forming process parameters corresponding to the target sleeve, identify the optimized process elements in the optimized forming process parameters, and formulate a parameter control scheme for the forming precision of the target sleeve based on the optimized process elements.

[0077] Based on the pressure gradient value, this invention optimizes the molding process parameters corresponding to the target sleeve, enabling the process parameters to accurately match the actual needs of impregnation and molding, enhancing the adaptability of parameters to material properties and pressure environment, effectively avoiding molding defects caused by parameter imbalance, and ensuring the stability and continuity of the entire molding process.

[0078] The molding process parameters refer to the comprehensive set of parameters that guide the complete molding process of the target sleeve, which integrates various requirements such as impregnation pressure level, rubber matrix viscosity, vulcanization reaction conditions and mold temperature curve. It covers the key operation standards of the entire process, including impregnation, vulcanization and shaping, including core indicators such as pressure, temperature, time and material properties.

[0079] As an embodiment of the present invention, optimizing the molding process parameters corresponding to the target sleeve based on the pressure gradient value includes: analyzing the impregnation pressure segment corresponding to the target sleeve according to the pressure gradient value; determining the slurry flow state corresponding to the target sleeve based on the impregnation pressure segment; adjusting the viscosity of the rubber matrix in the target sleeve according to the slurry flow state; setting the vulcanization reaction conditions corresponding to the target sleeve based on the adjusted rubber matrix viscosity; generating the mold temperature curve required for the target sleeve according to the vulcanization reaction conditions; and optimizing the molding process parameters corresponding to the target sleeve based on the mold temperature curve.

[0080] The impregnation pressure range refers to the pressure level intervals corresponding to different impregnation stages, divided according to the distribution range and variation characteristics of the pressure gradient values. Each range corresponds to a specific pressure range and target, reflecting the gradient change logic of pressure from initial application to stable maintenance and then to final adjustment during the impregnation process. The slurry flow state refers to the comprehensive characteristics of the slurry in the gaps between the target sleeve fibers, such as flow rate, penetration depth, filling rhythm, and distribution uniformity, based on the impregnation pressure range. It directly reflects the movement law and wetting effect of the slurry under the current pressure range and is closely related to the pressure gradient, fiber distribution, and the properties of the slurry itself. The rubber matrix viscosity refers to the physical properties of the rubber matrix in resisting flow and deformation. It is a key parameter affecting the slurry flow state and directly determines the slurry's viscosity. The penetration capacity and filling efficiency are related to the material composition, temperature, and degree of cross-linking. By adjusting these parameters, different impregnation pressure levels and slurry flow requirements can be adapted. The vulcanization reaction conditions refer to a set of key process parameters set based on the adjusted rubber matrix viscosity to ensure a full and stable vulcanization reaction. These parameters cover core elements such as the temperature range, holding time, pressure intensity, and environmental atmosphere of the vulcanization process. They need to be precisely matched with the rubber matrix viscosity to control the rate and extent of cross-linking reaction. The mold temperature curve refers to the dynamic trajectory of the mold temperature changing over time during the target sleeve molding process, generated according to the vulcanization reaction conditions. It includes key characteristics such as the heating rate, holding temperature and duration at each stage, and cooling rhythm. It is the specific implementation of the vulcanization reaction conditions in the molding process.

[0081] Furthermore, the analysis of the impregnation pressure segment corresponding to the target sleeve can be achieved through a pressure sensor data segmentation method, such as: dividing the time-series data collected by the pressure transmitter during the impregnation process into mean segments based on time windows, defining the initial impregnation, holding pressure, and pressure reduction stages, thereby obtaining the impregnation pressure segment; the determination of the slurry flow state corresponding to the target sleeve can be achieved through computational fluid dynamics two-phase flow simulation, such as: using the VOF model in ANSYS Fluent to simulate the change in the forward contact angle of the slurry in the fiber braid, thereby obtaining the slurry flow state; the adjustment of the viscosity of the rubber matrix in the target sleeve can be achieved through a plasticizer addition control method, such as: dynamically adjusting the addition ratio of silicone oil plasticizer through a metering pump based on the viscosity data monitored online by the rheometer. The viscosity of the rubber matrix is ​​obtained; the setting of the vulcanization reaction conditions corresponding to the target sleeve can be achieved by differential scanning calorimetry, such as: using a DSC analyzer to analyze the vulcanization exothermic peak of the rubber compound, determining the critical temperature and time threshold for initiating the crosslinking reaction, thereby obtaining the vulcanization reaction conditions; the mold temperature curve required to generate the target sleeve can be achieved by a PID temperature control algorithm, such as: setting a multi-segment heating-holding-cooling program based on vulcanization reaction kinetics in the PLC controller, and outputting it to the mold heating plate, thereby obtaining the mold temperature curve; the optimization of the molding process parameters corresponding to the target sleeve can be achieved by the Taguchi experimental design method, such as: arranging an L9 orthogonal array experiment, using wall thickness uniformity and interface strength as indicators, screening the optimal combination of key process parameters, thereby obtaining the molding process parameters.

[0082] In detail, after standardized testing, the specific experimental data comparison is as follows:

[0083] This invention identifies optimized process elements in the optimized molding process parameters, which can accurately pinpoint the core control points that play a key role in molding quality, making process optimization more targeted. This identification can eliminate interference from redundant parameters, avoid control deviations caused by ambiguity of key points, and ensure the high efficiency of process optimization.

[0084] The optimized process elements refer to the core process components in the optimized forming process parameters that play a decisive role in the precision forming quality and production efficiency of the target sleeve. They are key control points extracted from the optimized parameters of the entire process, including impregnation, vulcanization, and shaping. They cover key types such as pressure matching, temperature control, time allocation, and material performance adaptation, and are directly related to the structural integrity and performance stability of the product. Optionally, the identification of optimized process elements in the optimized forming process parameters can be achieved through main effect analysis methods, such as performing variance analysis on the signal-to-noise ratio results of the Taguchi experimental design to identify the two most significant factors, impregnation pressure and vulcanization temperature, thereby obtaining the optimized process elements.

[0085] Furthermore, based on the optimized process elements, the present invention formulates a parameter control scheme for the precision forming of the target sleeve, which enables the control logic to focus on the core control points, achieve precise control of the forming process, enhance the adaptability of the scheme to the precision forming requirements of the product, effectively avoid the blindness of parameter control, avoid forming deviations caused by the ambiguity of control focus, and ensure the stability and controllability of the production process.

[0086] The parameter control scheme refers to a systematic parameter management scheme specifically adapted to the precision requirements of the target sleeve forming, based on optimized process elements. It clarifies the control standards, threshold ranges, dynamic adjustment logic, and execution priorities of the core parameters throughout the forming process, covering specific control requirements for key optimization elements such as impregnation pressure, vulcanization temperature, and material viscosity. This scheme integrates the core results of process optimization, providing clear guidance for standardized execution, real-time monitoring, and dynamic correction of parameters. It can effectively avoid control deviations and ensure that the forming process always revolves around the precision forming goal. It is a core technical document for consolidating the effectiveness of process optimization. Optionally, the parameter control scheme for the precision forming of the target sleeve can be implemented through a digital twin modeling method, such as building a virtual model of the forming production line in a TPS tool, integrating the optimized process parameters into the control logic, and verifying them to obtain the parameter control scheme.

[0087] Specifically, the parameter control scheme enables precise control over the entire process of target sleeve forming. By optimizing process elements, the control standards and threshold ranges of core parameters are clearly defined, allowing for effective regulation of key parameters such as impregnation pressure, vulcanization temperature, and material viscosity. Through the establishment of dynamic adjustment logic, the parameter control scheme can adapt to minor fluctuations in the production process in real time, effectively avoiding forming defects caused by parameter deviations, and ensuring the structural integrity and performance stability of the product. At the same time, the scheme transforms optimization results into standardized execution guidelines, reducing human error, improving the controllability and repeatability of the production process, continuously consolidating the effectiveness of process optimization, and promoting the simultaneous improvement of the precision and production efficiency of target sleeve forming.

[0088] Compared to the problems described in the background art, this invention, by obtaining the initial production process corresponding to the target sleeve, can provide a precise benchmark for subsequent molding control, ensuring that process optimization has a clear starting point. It can directly identify the core basic conditions of production, reduce deviations caused by adjustments without a basis, and improve the targeting of control. Simultaneously, this step can anchor key production prerequisites in advance, helping to ensure the stability of product molding quality. Based on the rheological behavior pattern, this invention detects the real-time deformation state of the target sleeve in the preset molding production line, allowing the state perception during the molding process to closely match the actual dynamics, accurately capturing the core characteristics of morphological changes, and promptly identifying potential morphological anomalies. This avoids molding problems caused by the accumulation of deviations, ensuring the stability of the molding process. Furthermore, based on the heat conduction characteristics, this invention quantifies the heat accumulation effect value of the target sleeve in the vulcanization scenario, transforming the abstract heat accumulation state into a precisely quantifiable value. By controlling quantitative indicators and clearly understanding the cumulative pattern of heat distribution, this invention can promptly identify potential risks of excessive or uneven heat accumulation, avoiding product defects caused by thermal imbalance during vulcanization and ensuring the stability of the vulcanization stage. Furthermore, based on the aforementioned thermal stress level value, this invention determines the optimal crosslinking process for the target sleeve in the molding production line, enabling the crosslinking process to precisely adapt to the thermal stress distribution state, effectively avoiding structural defects caused by stress imbalance. It allows for targeted control of each stage of crosslinking, helping to solidify the quality foundation of the target sleeve's precision molding from the crosslinking stage. Finally, based on the aforementioned pressure gradient value, this invention optimizes the molding process parameters corresponding to the target sleeve, allowing the process parameters to accurately match the actual needs of impregnation and molding, strengthening the adaptability of parameters to material properties and pressure environment, effectively avoiding molding defects caused by parameter imbalance, and ensuring the stability and continuity of the entire molding process. Therefore, the precision molding control method and system for silicone rubber glass fiber sleeves provided by this invention can improve the molding accuracy and reliability of silicone rubber glass fiber sleeves.

[0089] like Figure 2 The diagram shown is a functional block diagram of a precision molding control system for silicone rubber glass fiber sleeves according to the present invention.

[0090] The precision molding control system 200 for silicone rubber and glass fiber ferrules described in this invention can be installed in electronic devices. Depending on the functions implemented, the precision molding control system may include a channel generation module 201, a feature detection module 202, a degree calculation module 203, a gradient value optimization module 204, and a scheme formulation module 205. The modules described in this invention can also be referred to as units, which are a series of computer program segments that can be executed by the processor of an electronic device and perform a fixed function, and are stored in the memory of the electronic device.

[0091] In this embodiment of the invention, the functions of each module / unit are as follows: The pattern analysis module 201 is used to obtain the initial production process corresponding to the target sleeve, determine the slurry wetting interface corresponding to the target sleeve based on the initial production process, and analyze the rheological behavior pattern corresponding to the slurry wetting interface. The feature detection module 202 is used to detect the real-time deformation state of the target sleeve in the preset molding production line based on the rheological behavior mode, analyze the fiber-rubber composite structure of the target sleeve based on the real-time deformation state, and detect the thermal conductivity characteristics of each bonding layer in the fiber-rubber composite structure. The degree calculation module 203 is used to quantify the heat accumulation effect value of the target sleeve in the vulcanization scenario based on the heat conduction characteristics, and to calculate the thermal stress degree value of the target sleeve in each vulcanization stage based on the heat accumulation effect value. The gradient value optimization module 204 is used to determine the optimal crosslinking process of the target sleeve in the molding production line based on the thermal stress level value, detect the material effect term corresponding to the optimal crosslinking process, and optimize the pressure gradient value of the target sleeve in the preset impregnation pressure field based on the material effect term. The scheme formulation module 205 is used to optimize the forming process parameters corresponding to the target sleeve based on the pressure gradient value, identify the optimized process elements in the optimized forming process parameters, and formulate a parameter control scheme for the target sleeve regarding forming precision based on the optimized process elements.

[0092] In detail, the modules in the precision molding control system 200 for silicone rubber glass fiber sleeves described in this embodiment of the invention employ the same methods as described above during use. Figure 1 The same technical means are used as described in the precision molding control method for silicone rubber glass fiber sleeves, and can produce the same technical effect, so they will not be repeated here.

[0093] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0094] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. In the above multiple embodiments, each embodiment can be combined with each other or independent. Deleting any one of them will not affect the technical implementation of other embodiments. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for precision molding and control of silicone rubber glass fiber sleeves, characterized in that, The method includes: Obtain the initial production process corresponding to the target casing, determine the slurry wetting interface corresponding to the target casing based on the initial production process, and analyze the rheological behavior mode corresponding to the slurry wetting interface. Based on the rheological behavior pattern, the real-time deformation state of the target sleeve in the preset molding production line is detected. Based on the real-time deformation state, the fiber-rubber composite structure of the target sleeve is analyzed, and the thermal conductivity characteristics of each bonding layer in the fiber-rubber composite structure are detected. Based on the aforementioned heat conduction characteristics, the heat accumulation effect value of the target sleeve under the vulcanization scenario is quantified, and based on the heat accumulation effect value, the thermal stress level value of the target sleeve at each vulcanization stage is calculated. Based on the thermal stress level value, the optimal crosslinking process of the target sleeve in the molding production line is determined, the material effect term corresponding to the optimal crosslinking process is detected, and the pressure gradient value of the target sleeve in the preset impregnation pressure field is optimized based on the material effect term. Based on the pressure gradient value, the forming process parameters corresponding to the target sleeve are optimized, the optimized process elements in the optimized forming process parameters are identified, and based on the optimized process elements, a parameter control scheme for the forming precision of the target sleeve is formulated.

2. The method for precision molding and control of silicone rubber glass fiber sleeves as described in claim 1, characterized in that, The process of determining the optimal crosslinking flow of the target sleeve in the molding production line based on the thermal stress level value includes: Based on the stated thermal stress level values, analyze the thermal stress distribution at each vulcanization stage; Based on the aforementioned thermal stress distribution, query the stress concentration area of ​​the current crosslinking process; For the stress concentration area, adjust the temperature setting of the vulcanizing equipment in the molding production line; Based on the adjusted temperature settings, the vulcanization time for each vulcanization stage is redistributed. By integrating the temperature setting and the vulcanization time, the optimal crosslinking process for the target sleeve in the molding production line is determined.

3. The method for precision molding and control of silicone rubber glass fiber sleeves as described in claim 2, characterized in that, The step of adjusting the temperature setting of the vulcanizing equipment in the molding production line for the stress concentration area includes: Analyze the regional distribution details corresponding to the stress concentration area; Based on the detailed regional distribution, analyze the abnormal transmission values ​​in the stress concentration region; Based on the abnormal transmission value, query the partition compensation amount of the vulcanizing equipment in the molding production line; Based on the zoning compensation amount, the heating power of each temperature zone of the vulcanizing equipment is set; Based on the heating power, adjust the temperature setting of the vulcanizing equipment in the molding production line.

4. The method for precision molding and control of silicone rubber glass fiber sleeves as described in claim 1, characterized in that... Determining the slurry wetting interface corresponding to the target casing includes: Analyze the set of process parameters in the initial production process; Based on the set of process parameters, extract the slurry formulation information corresponding to the target casing; Based on the slurry formulation information, analyze the rheological properties of the slurry in the initial production process; Based on the rheological performance indicators, the wetting conditions of the fiber surface corresponding to the target sleeve are identified; Based on the aforementioned wetting conditions, the slurry wetting interface corresponding to the target casing is determined.

5. The method for precision molding and control of silicone rubber glass fiber sleeves as described in claim 1, characterized in that, The analysis of the fiber-rubber composite structure corresponding to the target sleeve based on the real-time deformation state includes: Extract the deformation data from the real-time deformation state; Based on the deformation data, locate the fiber distribution area corresponding to the target sleeve; Scan the fiber orientation information in the fiber distribution area; Based on the fiber orientation information, determine the rubber filling state corresponding to the target sleeve; Based on the rubber filling state, the fiber-rubber composite structure corresponding to the target sleeve is analyzed.

6. The method for precision molding and control of silicone rubber glass fiber sleeves as described in claim 1, characterized in that, The step of quantifying the heat accumulation effect value of the target sleeve in a vulcanization scenario based on the heat conduction characteristics includes: Based on the aforementioned thermal conduction characteristics, the thermal conductivity values ​​between the layers of the target sleeve are analyzed. Based on the thermal conductivity value, the heat flux index of the bonding layer under the vulcanization scenario is analyzed. Based on the heat flux index, the temperature distribution value of the target sleeve during the vulcanization process is determined; Based on the temperature distribution value, query the amount of heat accumulation in the target sleeve; Based on the amount of heat accumulation, the heat accumulation effect value of the target sleeve in the vulcanization scenario is quantified.

7. The method for precision molding and control of silicone rubber glass fiber sleeves as described in claim 1, characterized in that, The calculation of the thermal stress level of the target sleeve at each vulcanization stage based on the heat accumulation effect value includes: Divide the target casing into independent vulcanization periods; Extract the time-period heat distribution within the independent vulcanization periods; Based on the heat distribution during the specified time period, analyze the interlayer temperature difference corresponding to the target casing; Based on the interlayer temperature difference, the difference in expansion between the rubber and the fiber in the target sleeve is determined; Based on the aforementioned expansion differences, the thermal stress level of the target casing at each vulcanization stage is calculated using the following formula. in, This indicates the degree of thermal stress in the target casing at each vulcanization stage. This indicates the total number of vulcanization stages. Indicating the number of vulcanization stages, This indicates the total number of bonding layers corresponding to the target sleeve. Indicates the index of the number of layers. This represents the equivalent elastic modulus of the j-th bonding layer. This represents the difference in expansion between the rubber and the fiber at the j-th bonding layer during the i-th vulcanization stage.

8. The method for precision molding and control of silicone rubber glass fiber sleeves as described in claim 1, characterized in that, The step of optimizing the pressure gradient value of the target sleeve in the preset impregnation pressure field based on the material effect term includes: Analyze the slurry rheological parameters in the material effect term; Based on the rheological parameters of the slurry, the current pressure in the preset impregnation pressure field is analyzed; Based on the current pressure conditions, the wetting uniformity of the target sleeve is detected; Based on the aforementioned wetting uniformity, the target pressure value of the preset impregnation pressure field is determined; Based on the target pressure value, the pressure gradient value of the target sleeve in the preset impregnation pressure field is optimized.

9. The method for precision molding and control of silicone rubber glass fiber sleeves as described in claim 1, characterized in that, The step of optimizing the forming process parameters corresponding to the target sleeve based on the pressure gradient value includes: Based on the pressure gradient value, analyze the immersion pressure segment corresponding to the target casing; Based on the impregnation pressure range, the slurry flow state corresponding to the target casing is determined; Adjust the viscosity of the rubber matrix in the target sleeve according to the slurry flow state; Based on the adjusted rubber matrix viscosity, the vulcanization reaction conditions corresponding to the target sleeve are set. Based on the vulcanization reaction conditions, the mold temperature profile required to generate the target sleeve is as follows; Based on the mold temperature curve, the forming process parameters corresponding to the target sleeve are optimized.

10. A precision molding control system for silicone rubber glass fiber sleeves, characterized in that, The system is used to perform a precision molding control method for silicone rubber glass fiber sleeves as described in any one of claims 1-9, the system comprising: The pattern analysis module is used to obtain the initial production process corresponding to the target casing, determine the slurry wetting interface corresponding to the target casing based on the initial production process, and analyze the rheological behavior pattern corresponding to the slurry wetting interface. The feature detection module is used to detect the real-time deformation state of the target sleeve in the preset molding production line based on the rheological behavior pattern, analyze the fiber-rubber composite structure of the target sleeve based on the real-time deformation state, and detect the thermal conductivity characteristics of each bonding layer in the fiber-rubber composite structure. The degree calculation module is used to quantify the heat accumulation effect value of the target sleeve in the vulcanization scenario based on the heat conduction characteristics, and to calculate the thermal stress degree value of the target sleeve in each vulcanization stage based on the heat accumulation effect value. The gradient value optimization module is used to determine the optimal crosslinking process of the target sleeve in the molding production line based on the thermal stress level value, detect the material effect term corresponding to the optimal crosslinking process, and optimize the pressure gradient value of the target sleeve in the preset impregnation pressure field based on the material effect term. The scheme formulation module is used to optimize the forming process parameters corresponding to the target sleeve based on the pressure gradient value, identify the optimized process elements in the optimized forming process parameters, and formulate a parameter control scheme for the target sleeve regarding forming precision based on the optimized process elements.

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