Color difference self-adaptive monitoring method and system in rubber color glue production process

Abstract

The invention relates to the technical field of industrial automation control, in particular to a color difference self-adaptive monitoring method and system in the rubber color glue production process, and the method comprises the steps: obtaining the real-time temperature and the real-time chromatic value in the rubber color glue production process, and the reference temperature and the reference chromatic value set by the production technology; taking a difference value between the real-time chromatic value and the standard chromatic value as a control deviation; real-time current and reference working current of a driving motor of the stirring equipment are obtained; and based on the control deviation and an improved PID control algorithm, outputting the valve opening degree of a pigment dropwise adding pump, and based on the valve opening degree, correcting the color difference in the rubber color glue production process. The problems of low production efficiency and poor quality stability are solved.

Description

Technical Field

[0001] This invention relates to the field of industrial automation control technology. More specifically, this invention relates to a method and system for adaptive monitoring of color difference during the production of rubber colorants. Background Technology

[0002] Rubber colorants, as an important raw material in industrial production, are mostly used in the manufacture of tires, seals, and functional rubber products. Their color uniformity and consistency directly affect the product's appearance quality and performance. In actual production, the quality of rubber colorants is affected by a combination of factors, including differences in color and physical properties between batches of raw materials, fluctuations in the rheological properties of the rubber base material itself, potential deviations in speed or load during the operation of mixing equipment, and slight deviations in the temperature control of the production line. These factors, when combined during production, can easily lead to a decrease in the uniformity of the rubber colorant during mixing, stirring, and conveying, resulting in a deviation from the preset standard in color of the final product, causing significant color difference problems. Color difference not only reduces the product's appearance quality but may also cause quality risks such as performance instability and structural inhomogeneity during subsequent processing, molding, or use. In severe cases, it can even affect the pass rate of the entire production batch and market reputation.

[0003] In existing rubber colorant production processes, traditional proportional-integral-derivative (PID) control algorithms are typically relied upon to adjust and manage key process parameters on the production line. These parameters mainly include temperature control of production equipment, speed regulation of mixers, and monitoring of some auxiliary process variables. The basic idea of ​​this control strategy is to achieve stable maintenance of the entire production process through continuous feedback and adjustment of a single process parameter, ensuring that the rubber colorant approaches the predetermined process objectives as closely as possible during mixing, stirring, and conveying.

[0004] However, traditional PID control parameters are fixed and lack the ability to perceive the instantaneous rheological state and fluctuation characteristics of the production process in real time. This makes it prone to response lag, overshoot, or oscillation under conditions of process disturbances, equipment inertia, or sudden changes in material viscosity. When temperature or stirring load becomes abnormal, the fixed proportional, integral, and derivative gains cannot be dynamically adjusted according to the actual fluctuation intensity, resulting in insufficient or excessive compensation for color difference changes. Consequently, the produced rubber colorants cannot maintain uniform color, leading to low production efficiency and poor quality stability. Summary of the Invention

[0005] To address the problems of low production efficiency and poor quality stability mentioned in the background art, the present invention provides solutions in the following aspects.

[0006] In a first aspect, the present invention provides a method for adaptive monitoring of color difference during the production of rubber pigments, comprising: acquiring real-time temperature, real-time chromaticity value, reference temperature and reference chromaticity value set in the production process, and using the difference between the real-time chromaticity value and the standard chromaticity value as a control deviation; acquiring the real-time current and reference operating current of the driving motor of the stirring equipment; outputting the valve opening of the pigment dripping pump based on the control deviation and an improved PID control algorithm, and correcting the color difference during the production of rubber pigments based on the valve opening; wherein the improved PID control algorithm includes proportional gain. Integral gain and differential gain parameter The proportional gain Integral gain Differential gain All are positively correlated with the degree of fluctuation at the current time point; the degree of fluctuation is positively correlated with the set reference inertia value and negatively correlated with the degree of dynamic rheology at the current time point; the degree of dynamic rheology is positively correlated with the real-time temperature and negatively correlated with the difference between the reference temperature, the real-time current and the reference operating current.

[0007] The aforementioned technical solution establishes an adaptive, real-time color difference control mechanism by multi-dimensionally coupling key process parameters such as temperature, rheological state, stirring load, and color deviation during the rubber colorant production process. This enables refined and dynamic management of the production process. This linked control not only responds quickly to color deviations caused by production fluctuations and differences in raw material characteristics, avoiding the lag and overshoot problems of traditional fixed-parameter control, but also maintains steady-state accuracy under stable operating conditions. This significantly improves the color consistency of the rubber colorant and the controllability of the production process, achieving efficient, continuous, and automated color difference management.

[0008] Furthermore, the proportional gain for: , As the reference proportional gain, for The degree of fluctuation at each point in time, The set reference inertia value.

[0009] The above technical solution dynamically correlates the proportional gain of the controller with the real-time fluctuation of the production process, thereby achieving adaptive adjustment of the system deviation response speed. When the fluctuation in the production process increases, the proportional gain will be appropriately amplified, thereby improving the control system's immediate response capability to deviation changes and accelerating the correction speed of temperature, mixing uniformity, and color deviation. When the system operation tends to be stable, the proportional gain will not be excessively amplified, avoiding oscillation or overshoot, thus maintaining the steady-state accuracy of the system while ensuring a fast response.

[0010] Furthermore, the integral gain for: , As the reference integral gain, for The degree of fluctuation at each point in time, The set reference inertia value.

[0011] The above technical solution establishes an inverse correlation between the integral gain of the controller and the real-time fluctuation of the production process, enabling the integral action to be dynamically adjusted according to the current stability of the system: when the production process fluctuates greatly, the integral action is weakened accordingly to avoid the accumulation of errors too quickly, which could lead to system overshoot or oscillation, thereby reducing the over-response to instantaneous disturbances; while when the system operation tends to be stable and the fluctuations are small, the integral action is enhanced to accelerate the correction of long-term deviations, eliminate steady-state errors, and improve the accuracy of temperature, mixing uniformity, and color.

[0012] Furthermore, the differential gain for: , As the reference differential gain, for The degree of fluctuation at each point in time, The set reference inertia value.

[0013] The above technical solution dynamically correlates the differential gain of the controller with the real-time fluctuation of the production process, enabling the differential action to adaptively adjust according to the rate of change of system deviation: when the fluctuation in the production process increases, the differential action increases accordingly, thereby increasing the suppression of the deviation change trend, quickly slowing down the growth rate of temperature, mixing unevenness or color deviation, and effectively suppressing system oscillation and overshoot; while when the system is running relatively smoothly, the differential action will not be excessively amplified, avoiding excessive response to small disturbances.

[0014] Furthermore, The degree of fluctuation at time points for: , The set reference inertia value, For the natural constant An exponential function with base 0. for The degree of dynamic change at a given time point.

[0015] The above technical solution maps the dynamic rheological state of the production process to the degree of system fluctuation, thereby achieving sensitive adjustment of the mixing and flow characteristics of rubber colorants. The more active the dynamic rheological state, the smaller the system's fluctuation response will be, thus avoiding overreaction to instantaneous disturbances. When the rheological state tends to be sluggish or uneven, the degree of fluctuation will be amplified, enhancing the ability to perceive and respond to abnormal working conditions.

[0016] Furthermore, The degree of dynamic change at time points for: , for Temperature during the production process of rubber colorant at specific time points The reference temperature set for the production process. For the natural constant An exponential function with base 0. for Current during the production process of rubber colorant at specific time points. This is the reference operating current for the drive motor of the mixing equipment.

[0017] The aforementioned technical solution establishes a dynamic rheological characterization by coupling the temperature during the rubber colorant production process with the current of the mixing equipment. This enables real-time quantitative evaluation of material flowability and mixing uniformity. Temperature changes reflect the viscoelasticity and softening degree of the material, while deviations in motor current reflect changes in the mixing load and shear resistance. Exponential modulation is used to reflect the suppressive effect of abnormal loads on the rheological state, thus forming a sensitive response to the production process status. This dynamic rheological index accurately reflects the instantaneous flow characteristics and physical behavior of the rubber colorant under different production conditions, allowing the control system to promptly detect potential anomalies when process parameters deviate from the target.

[0018] Furthermore, real-time colorimetric values ​​are obtained using an online colorimeter, and real-time temperature is obtained using a temperature sensor.

[0019] Furthermore, it also includes time-aligned processing of real-time temperature, real-time chromaticity value, and real-time current.

[0020] Furthermore, the PID control algorithm adopts an incremental PID control algorithm.

[0021] In a second aspect, the present invention provides a color difference adaptive monitoring system for the production process of rubber color adhesive, including a memory and a processor. The memory stores computer program instructions, and when the computer program instructions are executed by the processor, the color difference adaptive monitoring method for the production process of rubber color adhesive described in any one of the above embodiments is implemented.

[0022] The beneficial effects of this invention are as follows:

[0023] This invention constructs an adaptive, real-time adjustable color difference monitoring and correction system by multi-dimensionally coupling key parameters such as temperature, rheological state, motor load, and real-time colorimetry during the rubber pigment production process. This achieves refined management and intelligent control of the production process. In this invention, color difference deviations can be captured instantly, and the dynamic rheological degree and fluctuation state are quantified for adaptive adjustment of the proportional, integral, and derivative gains of the PID controller. This enables precise control of the opening of the pigment dispensing pump valve, allowing for rapid and effective correction of colorimetry deviations during the mixing and stirring of the pigment. This not only enhances the system's responsiveness to production fluctuations, raw material differences, and instantaneous disturbances caused by equipment inertia, but also maintains high-precision colorimetry control under steady-state conditions. It significantly improves the color uniformity and consistency of the rubber pigment, increases production efficiency and the reliability of continuous production, and provides an efficient, automated, and physically meaningful means of color difference control for the rubber pigment production process. Attached Figure Description

[0024] Figure 1 This is a flowchart illustrating an adaptive monitoring method for color difference during the production of rubber colorant according to an embodiment of the present invention; Figure 2 This is a schematic diagram illustrating the comparison of the color difference correction effect before and after using the color difference adaptive monitoring method in the production process of rubber color glue according to an embodiment of the present invention; Figure 3 This is a schematic diagram illustrating the structural block diagram of a color difference adaptive monitoring system in the rubber coloring process according to an embodiment of the present invention. Detailed Implementation

[0025] Example of an adaptive monitoring method for color difference during the production of rubber colorants.

[0026] like Figure 1 The flowchart shown below illustrates the color difference adaptive monitoring method during the rubber colorant production process according to an embodiment of the present invention, which includes the following steps: S1: Obtain the real-time temperature, real-time color value, reference temperature and reference color value set in the production process of rubber color glue, and at the same time obtain the real-time current and reference working current of the drive motor of the stirring equipment.

[0027] In a preferred embodiment, the real-time temperature is preferably acquired by a high-precision temperature sensor installed inside the mixing vessel or reaction vessel to reflect the actual thermal environment state of the colorant system at the current time point; the reference temperature is a standard temperature pre-set based on the target formulation and process experience, used as a benchmark for temperature deviation analysis. By comparing the real-time temperature with the reference temperature, the thermal stability and thermal deviation of the current production process can be effectively characterized, providing reliable input for subsequent control strategies.

[0028] The real-time colorimetric value is preferably obtained through an online colorimeter, used to output the colorimetric parameters of the rubber colorant during the production process in real time. The reference colorimetric value is a standard colorimetric parameter corresponding to the quality requirements of the target product, used as a benchmark value for color difference calculation and quality judgment. By continuously collecting and comparing the real-time colorimetric value and the reference colorimetric value, the color evolution trend of the colorant during mixing, dispersion, and reaction processes can be dynamically reflected, thereby avoiding the quality risk of lag caused by relying solely on final inspection. At the same time, the real-time current of the driving motor of the stirring equipment is acquired. The real-time current is used to characterize the changes in material viscosity, shear resistance, and load fluctuations during the stirring process. The reference working current is a reference current value pre-calibrated under stable operating conditions or standard production conditions. By comparing and analyzing the real-time current and the reference working current, the changes in the rheological properties and the degree of mixing uniformity of the rubber colorant system at the current moment can be indirectly reflected, providing auxiliary criteria for judging the dispersion state of the colorant and process abnormalities.

[0029] Furthermore, the real-time temperature, real-time colorimetric value, and real-time current are synchronized and time-aligned to eliminate the impact of inconsistent sampling frequencies of multiple sensors, communication delays, and differences in data refresh cycles on subsequent analysis.

[0030] Specifically, by introducing a unified system timestamp mechanism, the raw data from temperature sensors, colorimetry detection devices, and motor current acquisition modules are time-stamped. Subsequently, based on a preset time alignment window or time interpolation strategy, the multi-source data acquired at different sampling frequencies are mapped to the same time axis, constructing a parameter combination with physical consistency at the same time node.

[0031] S2: Outputs the valve opening of the pigment drip pump based on control deviation and an improved PID control algorithm.

[0032] In a preferred embodiment, the PID control algorithm employs an incremental PID control algorithm, and the improved PID control algorithm includes proportional gain control. Integral gain and differential gain parameter The proportional gain for: , As the reference proportional gain, for The degree of fluctuation at each point in time, The set reference inertia value.

[0033] The integral gain for: , As the reference integral gain, for The degree of fluctuation at each point in time, The set reference inertia value.

[0034] The differential gain for: , As the reference differential gain, for The degree of fluctuation at each point in time, The set reference inertia value.

[0035] By coupling controller parameters with the degree of fluctuation in a closed loop, an adaptive incremental control mechanism with state-aware capabilities is constructed. Based on the baseline control parameters, the proportional, integral, and derivative actions are differentially modulated according to the strength of fluctuations in the current production process: when fluctuations increase, the proportional and derivative adjustment strengths are simultaneously amplified to accelerate the response speed to changes in deviations and suppress trend diffusion, while the integral action is weakened to avoid overshoot caused by cumulative effects under unstable conditions; conversely, when the operation tends to be stable, the integral adjustment capability is relatively enhanced to improve steady-state accuracy and eliminate long-term deviations. Through this linked parameter adjustment method, the control algorithm can achieve a dynamic balance between stability and responsiveness. This reduces the problems of oscillation and overshoot that traditional fixed-parameter control is prone to under strong fluctuations, and avoids slow response or insufficient adjustment in the stable phase. As a result, it significantly improves the adaptability of the rubber colorant production process to disturbances such as temperature and load, control robustness, and consistency of finished product quality.

[0036] The degree of fluctuation at time points for: , The set reference inertia value, For the natural constant An exponential function with base 0. for The degree of dynamic change at a given time point.

[0037] By establishing a nonlinear mapping relationship between fluctuation characteristics and dynamic rheological degree, and utilizing the monotonically decreasing characteristic of the exponential function, when rheological activity is high and material flow and dispersion are good, the equivalent inertia to disturbances is compressed, thereby reducing the amplification effect on instantaneous disturbances. Conversely, when the rheological state tends to be sluggish or rigid, the exponential term increases significantly, amplifying the fluctuation degree above the baseline level, thus enhancing the response sensitivity to abnormal operating conditions. This approach avoids system oscillations caused by over-adjustment under stable operating conditions and can amplify fluctuation signals in a timely manner at the initial stage of rheological deterioration, enabling early detection and suppression of process instability trends.

[0038] The degree of dynamic change at time points for: , for Temperature during the production process of rubber colorant at specific time points The reference temperature set for the production process. For the natural constant An exponential function with base 0. for Current during the production process of rubber colorant at specific time points. This is the reference operating current for the drive motor of the mixing equipment.

[0039] By coupling and modeling representative thermal state factors and mechanical load factors in the rubber colorant production process, a dynamic rheological characterization method with nonlinear modulation characteristics is constructed. Its core logic lies in utilizing the amplifying effect of temperature on the overall viscoelastic trend of the material, and forming a synergistic constraint relationship with the suppressive effect of stirring current on the internal shear resistance and dispersion uniformity of the system: when the temperature deviates from the process baseline, the rheological activity changes proportionally; and when the stirring load increases abnormally, the rheological response is rapidly suppressed through an exponential decay mechanism, thus avoiding misjudgments caused by fluctuations in a single parameter. This method not only more realistically reflects the instantaneous flow and dispersion state of rubber colorants under actual production conditions, but also identifies potential quality risks caused by temperature control instability, sudden changes in material viscosity, or abnormal equipment load at an early stage, providing a reliable, continuous, and physically meaningful decision-making basis for subsequent adaptive control and color difference stabilization control.

[0040] S3: And correct the color difference in the rubber coloring process based on the valve opening.

[0041] like Figure 2 The figure shown is a comparison of the color difference correction effects before and after using the color difference adaptive monitoring method in the rubber color glue production process according to an embodiment of the present invention.

[0042] In a preferred embodiment, by adjusting the opening of the control valve in real time during the production of rubber colorant, not only is precise control of material flow and mixing uniformity achieved, but the adjusted valve opening is also used as a feedback signal that directly affects the process parameters, and is used to dynamically correct color differences that occur during the production process.

[0043] Specifically, when a deviation of the colorant from the reference colorant value is detected, the control algorithm can calculate the correction range for material flow, mixing speed, and temperature distribution based on the change in valve opening. This achieves automatic color difference compensation, allowing the colorant to quickly approach a standard state in terms of component distribution and optical properties. It effectively suppresses local color deviations caused by batch differences in raw materials, equipment inertia, or process fluctuations, while avoiding the lag and unevenness of traditional manual adjustments. This significantly improves the automation level, process stability, and finished product color consistency of the production process, ensuring high-quality output of rubber colorants under continuous production conditions and providing quantifiable control data for subsequent color difference prediction and adaptive optimization.

[0044] This invention employs a multi-dimensional coupled analysis of temperature, stirring load, material rheological state, and real-time colorimetric data during the rubber colorant production process. This constructs an adaptive, dynamically adjustable color difference monitoring and correction mechanism. By combining online monitored colorimetric and temperature information with changes in motor load, the flow characteristics of the material and the degree of system fluctuation are calculated in real time. Based on this, the proportional, integral, and derivative actions of the PID controller are dynamically adjusted to output precise pigment dispensing valve openings, achieving immediate correction of color differences. Through this adaptive control strategy, the system can quickly respond to mixing unevenness or color deviation caused by temperature fluctuations, equipment inertia, and batch differences in raw materials during production. Simultaneously, it maintains steady-state accuracy under stable operating conditions, significantly improving the color consistency and mixing uniformity of the rubber colorant, enhancing production automation and quality reliability, and providing a stable, efficient, and intelligent control method for continuous, high-precision colorant production.

[0045] Example of a color difference adaptive monitoring system in the production process of rubber colorants: like Figure 3 As shown in the figure, the structural block diagram of the color difference adaptive monitoring system in the rubber color glue production process of this invention includes a processor and a memory.

[0046] This invention also provides a color difference adaptive monitoring system during the production of rubber colorants. For example... Figure 3 As shown, the system includes a processor and a memory. The memory stores computer program instructions, which, when executed by the processor, implement the color difference adaptive monitoring method in the rubber color glue production process according to the present invention.

[0047] The color difference adaptive monitoring system in the rubber color glue production process also includes other components well known to those skilled in the art, such as communication interfaces. Their settings and functions are known in the art, and therefore will not be described in detail here.

[0048] In this invention, the aforementioned memory can be any tangible medium containing or storing a program that can be used or combined with an instruction execution system, apparatus, or device. For example, a computer-readable storage medium can be any suitable magnetic or magneto-optical storage medium, such as Resistive Random Access Memory (RRAM), Dynamic Random Access Memory (DRAM), Static Random Access Memory (SRAM), Enhanced Dynamic Random Access Memory (EDRAM), High-Bandwidth Memory (HBM), Hybrid Memory Cube (HMC), etc., or any other medium that can be used to store desired information and can be accessed by an application, module, or both. Any such computer storage medium can be part of a device or accessible to or connected to a device. Any application or module described in this invention can be implemented using computer-readable / executable instructions stored or otherwise maintained by such a computer-readable medium.

[0049] In the description of this specification, "multiple" or "several" means at least two, such as two, three or more, unless otherwise explicitly specified.

[0050] While this specification has shown and described numerous embodiments of the invention, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Many modifications, alterations, and alternatives will occur to those skilled in the art without departing from the spirit and essence of the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in the practice of this invention.

Claims

1. A method for adaptive monitoring of color difference during the production of rubber colorants, characterized in that, include: The system acquires real-time temperature, real-time colorimetric value, reference temperature and reference colorimetric value set during the rubber color production process, and uses the difference between the real-time colorimetric value and the standard colorimetric value as the control deviation; it also acquires the real-time current and reference operating current of the stirring equipment drive motor. The valve opening of the pigment drip pump is output based on the control deviation and the improved PID control algorithm, and the color difference in the rubber color glue production process is corrected based on the valve opening. Among them, the improved PID control algorithm includes proportional gain. Integral gain and differential gain parameter The proportional gain Integral gain Differential gain All are positively correlated with the degree of fluctuation at the current time point; The degree of fluctuation is positively correlated with the set reference inertia value and negatively correlated with the dynamic rheological degree at the current time node; the degree of dynamic rheological degree is positively correlated with the real-time temperature and negatively correlated with the difference between the reference temperature, the real-time current and the reference operating current.

2. The color difference adaptive monitoring method in the rubber coloring process according to claim 1, characterized in that, The proportional gain for: , As the reference proportional gain, for The degree of fluctuation at each point in time, This is the set reference inertia value.

3. The color difference adaptive monitoring method in the rubber coloring process according to claim 1, characterized in that, The integral gain for: , As the reference integral gain, for The degree of fluctuation at each point in time, This is the set reference inertia value.

4. The method for adaptive monitoring of color difference during the production process of rubber colorant according to claim 1, characterized in that, The differential gain for: , As the reference differential gain, for The degree of fluctuation at each point in time, This is the set reference inertia value.

5. The method for adaptive monitoring of color difference during the production of rubber colorant according to claim 1, characterized in that, The degree of fluctuation at time points for: , The set reference inertia value, For the natural constant An exponential function with base 0. for The degree of dynamic change at a given time point.

6. The color difference adaptive monitoring method in the rubber coloring process according to claim 1, characterized in that, The degree of dynamic change at time points for: , for Temperature during the production process of rubber colorant at specific time points The reference temperature set for the production process. For the natural constant An exponential function with base 0. for Current during the production process of rubber colorant at specific time points. This is the reference operating current for the drive motor of the mixing equipment.

7. The color difference adaptive monitoring method in the rubber coloring process according to claim 1, characterized in that, Real-time colorimetric values ​​are obtained using an online colorimeter, and real-time temperature is obtained using a temperature sensor.

8. The method for adaptive monitoring of color difference during the production of rubber colorant according to claim 1, characterized in that, It also includes time-aligned processing of real-time temperature, real-time chromaticity value, and real-time current.

9. The method for adaptive monitoring of color difference during the production process of rubber colorant according to claim 1, characterized in that, The PID control algorithm used is an incremental PID control algorithm.

10. A color difference adaptive monitoring system for rubber colorant production process, characterized in that, It includes a memory and a processor, wherein the memory stores computer program instructions, and when the computer program instructions are executed by the processor, the color difference adaptive monitoring method in the rubber coloring process according to any one of claims 1 to 9 is implemented.

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