Feeding proportion monitoring and alarming device and method for double-component glue injection machine

Abstract

The invention discloses a feeding proportion monitoring and alarming device and method for a two-component glue injection machine. The feeding proportion monitoring and alarming device comprises an information monitoring module, a data acquisition and analysis module and a data pushing module, the information monitoring module is used for detecting the temperature and the liquid level of materials in a material storage tank and the temperature, the pressure and the flow of the materials in a pipeline and comprises a temperature sensor, a pressure sensor, an online flowmeter, a liquid level meter and a visual ruler. The data acquisition and analysis module is a PLC (Programmable Logic Controller) and is used for calculating the actual output flow of materials and analyzing the proportion of abnormal materials, and the PLC is in communication connection with a temperature sensor, a pressure sensor, an online flowmeter and a liquid level meter; the data pushing module is an Internet of Things card which is in communication connection with the data acquisition and analysis module. According to the invention, through multiple monitoring and calibration, the stable strength and the stable proportion of the glue injection machine are ensured.

Description

Technical Field

[0001] This invention relates to the field of two-component dispensing machine technology, and in particular to a two-component dispensing machine material feeding ratio monitoring and alarm device and method. Background Technology

[0002] Two-component dispensing machines, as specialized equipment for processing two-component epoxy resins, polyurethanes, and other materials, are widely used in high-performance fields such as automotive manufacturing and electronic packaging due to the excellent strength and abrasion resistance of the mixed materials. The accuracy of the adhesive ratio directly determines the performance of the cured product and is a core process parameter of the equipment; therefore, monitoring and optimizing the material supply ratio is crucial.

[0003] Two-component dispensing machines are specifically designed for mixing and injecting two different components of adhesives or resins. They require a high-precision metering system to mix the two components in a preset ratio, resulting in a mixed adhesive that meets performance requirements in various scenarios. The mixing ratio is a core process parameter; its accuracy directly affects the stability, consistency, and reliability of the dispensing effect. It needs to be dynamically adjusted based on the adhesive properties (viscosity, reactivity) and the production environment (temperature, humidity) to achieve high-precision dispensing operations.

[0004] In existing technologies, the flow rate calculated based on gear pump parameters is often a theoretical value. However, during actual operation, the flow rate displayed by the control system deviates significantly from the actual flow rate due to factors such as the accuracy of the pump manufacturer's data, gear wear, and changes in operating conditions. This can easily lead to a situation where the displayed ratio appears normal but the actual flow rate is unbalanced, resulting in excess rubber material or abnormal product performance.

[0005] Researchers also found that existing technologies cannot manually calculate the proportion of adhesive during the dispensing process in real time. The cause can only be traced after a product problem occurs, lacking real-time monitoring and early intervention capabilities. Furthermore, existing technologies often rely on weight-measuring equipment, but the weight-measuring components are subjected to long-term pressure and cannot be calibrated, resulting in low monitoring reliability. Additionally, component replacement is difficult, affecting the continuous and stable operation of the equipment. While some existing devices have alarm functions, they lack fault analysis capabilities and cannot combine multiple parameters to pinpoint the cause of the fault, leading to low maintenance efficiency and impacting production schedules. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a device and method for monitoring and alarming the material supply ratio of a two-component dispensing machine. Through multiple monitoring and calibration processes, this invention ensures stable power and material supply ratio of the dispensing machine.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a two-component dispensing machine material feeding ratio monitoring and alarm device, comprising: The information monitoring module is configured to collect rubber compound status data and equipment operation data, and transmit them to the data acquisition and analysis module. The data acquisition and analysis module is configured to: compare the device operating data according to a preset threshold, generate a liquid level abnormality alarm signal and transmit it to the data push module; calculate the actual output flow rate and actual mixing ratio of the material through the data acquisition and analysis module, compare the actual mixing ratio with the rubber ratio, and generate a ratio abnormality alarm signal if the deviation exceeds the threshold; at the same time, calculate the feedback flow rate, compare the actual output flow rate with the feedback flow rate, and generate a flow rate abnormality alarm signal if the deviation exceeds the threshold and transmit it to the data push module. The data push module is configured to transmit abnormal liquid level alarm signals, abnormal flow rate alarm signals, and abnormal ratio alarm signals to the terminal device to complete monitoring and alarm functions.

[0008] As a further technical solution, the information monitoring module includes a temperature sensor, a pressure sensor, an online flow meter, a level gauge, and a visual scale. The temperature sensor is installed on the material storage tank and pipeline of the two-component dispensing machine; the pressure sensor is installed at the outlet of the discharge pump and the outlet of the mixing pipe of the two-component dispensing machine; and the online flow meter is installed at the outlet of the mixing pipe.

[0009] As a further technical solution, the level gauge includes an in-tank level gauge and an external reference level gauge. The in-tank level gauge is installed inside the material storage tank, and the external reference level gauge is installed on the level pipe outside the material storage tank. Both the in-tank level gauge and the external reference level gauge are capacitive level gauges, and the external reference level gauge is matched with a visual scale.

[0010] As a further technical solution, the liquid level data collected by the external reference level gauge needs to be manually verified against the data obtained by the matching visual scale. If the deviation between the two exceeds the preset range, the external reference level gauge is calibrated to ensure the accuracy of the external reference level gauge data.

[0011] Secondly, the present invention provides a method for monitoring and alarming the feeding ratio of a two-component dispensing machine, based on the two-component dispensing machine feeding ratio monitoring and alarm device described in any one of the first aspects, comprising: Input the density parameter of the rubber compound into the data acquisition and analysis module according to its properties, and set the rubber compound ratio and the flow rate of the mixture according to the production process requirements. The information monitoring module collects data on the state of the rubber compound and the operation data of the equipment, and transmits them to the data acquisition and analysis module. The data acquisition and analysis module compares the device operating data with preset thresholds, generates a liquid level abnormality alarm signal, and transmits it to the data push module. The data acquisition and analysis module also calculates the actual output flow rate and actual mixing ratio of the material, compares the actual mixing ratio with the rubber ratio, and generates a ratio abnormality alarm signal if the deviation exceeds the threshold. At the same time, the feedback flow rate is calculated, and compared with the actual output flow rate. If the deviation exceeds the threshold, a flow rate abnormality alarm signal is generated and transmitted to the data push module. The data push module transmits abnormal liquid level alarm signals, abnormal flow rate alarm signals, and abnormal ratio alarm signals to the terminal device to complete the monitoring and alarm process.

[0012] As a further technical solution, the material state data includes the material temperature in the material storage tank and pipeline collected by a temperature sensor, and the mixed material flow rate at the mixing pipe outlet collected by an online flow meter; the device operation data includes the pressure at the discharge pump outlet and mixing pipe outlet collected by a pressure sensor, and the liquid level data of the material storage tank collected by a level gauge.

[0013] As a further technical solution, the formula for calculating the actual output flow rate of the material is as follows: ;in, This represents the actual output flow rate of the material. This refers to the actual output volume of the material. Liquid level drops The corresponding time, The diameter of the material storage tank. This refers to the height by which the liquid level drops.

[0014] As a further technical solution, the formula for calculating the actual mixing ratio is: ;in, , The output quality of material A and material B are respectively. , These are the actual output flow rates of material A and material B, respectively. , The densities of material A and material B are respectively. The calculation period is specified.

[0015] As a further technical solution, the formula for calculating the feedback flow is: ; ; in, To provide feedback on traffic, This refers to the single-revolution displacement of the gear pump. For the volume of a single tooth valley, This refers to the number of teeth on the gear. This refers to the gear pump speed. This refers to the volumetric efficiency of the gear pump.

[0016] As a further technical solution, it also includes: comparing the pressure at the outlet of the discharge pump and the outlet of the mixing pipe in the device operation data with the preset normal pressure; if the pressure exceeds the range, generating a pressure abnormality alarm signal and transmitting it to the data push module.

[0017] One or more technical solutions of the present invention have the following beneficial effects: This invention utilizes data collected by an information monitoring module to calculate the actual output flow rate of the material. This is combined with real-time calibration using both an in-tank level gauge and an external reference level gauge (with alarms for deviations exceeding set values). The external level gauge also features a visual scale for manual verification, forming a dual calibration mechanism. This design effectively avoids the impact of manufacturer data accuracy, gear wear, and changes in operating conditions on the theoretical flow rate of gear pumps, ensuring consistency between the displayed flow rate and actual data. This fundamentally prevents situations where the displayed ratio is normal but the actual flow rate is unbalanced, reducing material waste and product performance abnormalities.

[0018] This invention designs level gauges (in-tank level gauge and external reference level gauge) and a visual scale, enabling the display of real-time dispensing ratios. It also allows for flexible setting of comparison time periods such as 1 hour and 2 hours. Manual calculation of the consumption and ratio of materials A and B based on the displayed level data is possible, eliminating the need to wait for product problems to occur before tracing back. Manual verification provides a final guarantee for the accuracy of the dispensing ratio, allowing for immediate inspection and timely detection of ratio anomalies. Furthermore, this invention utilizes the liquid level to calculate flow rate by measuring the drop in liquid level, providing more stable and reliable level data compared to weight measurement elements that are constantly under pressure and cannot be calibrated. Simultaneously, the level gauges are easy to replace and calibrate, reducing equipment maintenance costs and downtime, and improving production efficiency.

[0019] This invention features a data push module that can push anomaly analysis and recommended troubleshooting order to operators, eliminating the need for manual troubleshooting, significantly shortening fault handling time, reducing production interruptions caused by faults, and ensuring continuous and stable glue injection operations. Attached Figure Description

[0020] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0021] Figure 1 This is a schematic diagram of a two-component dispensing machine material feeding ratio monitoring and alarm device according to the present invention; Detailed Implementation It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0022] Example 1 A typical two-component dispensing machine consists of a material storage tank, pipelines, a discharge pump, a control box, a dispensing gun, and temperature and pressure gauges. This device integrates the instruments of a conventional two-component dispensing machine and adds some new instruments. This invention provides a two-component dispensing machine material supply ratio monitoring and alarm device, including: an information monitoring module, a data acquisition and analysis module, and a data push module.

[0023] In this embodiment, the information monitoring module is used to detect the material temperature and liquid level in the material storage tank and the material temperature, pressure and flow rate in the pipeline. It includes a temperature sensor, a pressure sensor, an online flow meter, a liquid level gauge and a visual scale.

[0024] Specifically: temperature sensors are installed on the material storage tank and pipelines of the two-component dispensing machine; pressure sensors are installed at the outlet of the discharge pump and the outlet of the mixing pipe of the two-component dispensing machine; and an online flow meter is installed at the outlet of the mixing pipe. Furthermore, in this embodiment, the level gauge includes an in-tank level gauge and an external reference level gauge. The in-tank level gauge is installed inside the material storage tank, and the external reference level gauge is installed on the level pipe outside the material storage tank. Both the in-tank level gauge and the external reference level gauge are capacitive level gauges, and the external reference level gauge is matched with a visual scale.

[0025] The liquid level data collected by the external reference level gauge needs to be manually verified against the data obtained by the matching visual scale. If the deviation between the two exceeds the preset range, the external reference level gauge needs to be calibrated to ensure the accuracy of the external reference level gauge data.

[0026] In this embodiment, the data acquisition and analysis module is a PLC controller, and the PLC controller has a preset control program for receiving data from the information monitoring module, analyzing and monitoring the stability of the equipment through the program, calculating the actual output flow rate of the material and analyzing the proportion of abnormal materials based on the received data, and the PLC controller is communicatively connected to the temperature sensor, pressure sensor, online flow meter, and level gauge.

[0027] In this embodiment, the control program preset in the PLC controller is written into the PLC controller by the designer according to the specific function. There are many suppliers of PLC controllers to choose from. In this embodiment, Siemens SIMATIC S7-1200 is selected.

[0028] In this embodiment, the data push module is an IoT card and related devices. The IoT card is communicatively connected to the data acquisition and analysis module, and its function is to control the transponder to push alarm information to the computer and mobile phone.

[0029] Example 2 This embodiment provides a method for monitoring and alarming the material feeding ratio of a two-component dispensing machine, such as... Figure 1 As shown, based on the two-component dispensing machine feeding ratio monitoring and alarm device provided in Embodiment 1, the specific steps of the method are as follows: S1: Input the density parameter of the rubber compound into the data acquisition and analysis module according to the properties of the rubber compound, and set the rubber compound ratio and the flow rate of the mixture according to the production process requirements.

[0030] S2: The information monitoring module collects data on the state of the rubber compound and the operation data of the equipment, and transmits them to the data acquisition and analysis module.

[0031] In step S2, the material state data includes the material temperature in the material storage tank and pipeline collected by the temperature sensor, and the mixed material flow rate at the mixing pipe outlet collected by the online flow meter; the device operation data includes the pressure at the discharge pump outlet and mixing pipe outlet collected by the pressure sensor, and the liquid level data of the material storage tank collected by the level gauge.

[0032] S3: The data acquisition and analysis module compares the device operating data according to a preset threshold, generates a liquid level abnormality alarm signal, and transmits it to the data push module; it also calculates the actual output flow rate and actual mixing ratio of the material through the data acquisition and analysis module, compares the actual mixing ratio with the rubber ratio, and generates a ratio abnormality alarm signal if the deviation exceeds the threshold; at the same time, it calculates the feedback flow rate, compares the actual output flow rate with the feedback flow rate, and generates a flow rate abnormality alarm signal if the deviation exceeds the threshold, and transmits it to the data push module.

[0033] In step S3, capacitive level gauges (in-tank level gauge A-LT1 and in-tank level gauge B-LT1) are installed inside material storage tanks A and B to display the material level in real time and transmit the level signal to the PLC controller. Capacitive level gauges (out-of-tank reference level gauge A-LT0 and out-of-tank reference level gauge B-LT0) are installed on the external level tubes of material storage tanks A and B to display the material level in real time and transmit the level signal to the PLC controller as information for flow statistics. The external level gauges serve as reference level gauges, and visual scales (A-TI and B-TI) are installed on the external level tubes in conjunction with the external reference level gauges. The level transmitted by the external reference level gauges (A-LT0 and B-LT0) is compared with the visual scales (A-TI and B-TI) to calibrate the accuracy of the transmitted signal. When the output data of the in-tank level gauge deviates from the output data of the external reference level gauge by more than 5% (adjustable range), an abnormal level alarm signal is generated and transmitted to the data push module.

[0034] In step S3, the formula for calculating the actual output flow rate of the material is: ;in, This represents the actual output flow rate of the material. This refers to the actual output volume of the material. Liquid level drops The corresponding time, The diameter of the material storage tank. This refers to the height by which the liquid level drops.

[0035] The formula for calculating the actual mixing ratio is: ;in, , The output quality of material A and material B are respectively. , These are the actual output flow rates of material A and material B, respectively. , The densities of material A and material B are respectively. The calculation period is specified.

[0036] The formula for calculating the feedback flow is: ; ; in, To provide feedback on traffic, This refers to the single-revolution displacement of the gear pump. For the volume of a single tooth valley, This refers to the number of teeth on the gear. This refers to the gear pump speed. This refers to the volumetric efficiency of the gear pump.

[0037] Comparing the actual output flow rate with the feedback flow rate, if the deviation exceeds 5% (range adjustable), a flow abnormality alarm signal is generated and transmitted to the data push module. Possible causes of the abnormality include: pump malfunction (gear wear, abnormal speed, etc.), blockage of the injection pipe, blockage of the mold injection port, blockage of the pre- and post-pump pipelines, and viscosity changes due to abnormal material temperature. Analysis can be performed using parameters such as material temperature, pipeline pressure, feedback flow rate, and mixture flow rate. Simultaneously, combined with fault statistics, fault information and troubleshooting sequence are pushed to the operator.

[0038] Step S3 also includes: comparing the pressure at the outlet of the discharge pump and the outlet of the mixing pipe in the device operation data with the preset normal pressure; if the pressure exceeds the range, generating a pressure abnormality alarm signal and transmitting it to the data push module.

[0039] Possible causes of abnormal pressure include: flow fluctuations caused by pump malfunction (tooth wear, abnormal speed, etc.), pressure increases caused by blockage of the injection pipe and mold injection port, and pressure decreases or increases caused by blockage of pipelines before and after the pump. These can be analyzed using parameters such as material temperature, pipeline pressure, feedback flow, and mixed material flow. At the same time, combined with fault statistics, fault information and troubleshooting sequence can be pushed to the operators.

[0040] S4: The data push module transmits the abnormal liquid level alarm signal, abnormal flow rate alarm signal, and abnormal ratio alarm signal to the terminal device to complete the monitoring and alarm.

[0041] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A two-component dispensing machine material feeding ratio monitoring and alarm device, characterized in that, include: The information monitoring module is configured to collect rubber compound status data and equipment operation data, and transmit them to the data acquisition and analysis module. The data acquisition and analysis module is configured to: compare the device operating data according to a preset threshold, generate a liquid level abnormality alarm signal and transmit it to the data push module; calculate the actual output flow rate and actual mixing ratio of the material through the data acquisition and analysis module, compare the actual mixing ratio with the rubber ratio, and generate a ratio abnormality alarm signal if the deviation exceeds the threshold; at the same time, calculate the feedback flow rate, compare the actual output flow rate with the feedback flow rate, and generate a flow rate abnormality alarm signal if the deviation exceeds the threshold and transmit it to the data push module. The data push module is configured to transmit abnormal liquid level alarm signals, abnormal flow rate alarm signals, and abnormal ratio alarm signals to the terminal device to complete monitoring and alarm functions.

2. The two-component dispensing machine feeding ratio monitoring and alarm device as described in claim 1, characterized in that, The information monitoring module includes a temperature sensor, a pressure sensor, an online flow meter, a level gauge, and a visual scale. The temperature sensor is installed on the material storage tank and pipeline of the two-component dispensing machine; the pressure sensor is installed at the outlet of the discharge pump and the outlet of the mixing pipe of the two-component dispensing machine; and the online flow meter is installed at the outlet of the mixing pipe.

3. The two-component dispensing machine feeding ratio monitoring and alarm device as described in claim 2, characterized in that, The level gauge includes an in-tank level gauge and an external reference level gauge. The in-tank level gauge is installed inside the material storage tank, and the external reference level gauge is installed on the level pipe outside the material storage tank. Both the in-tank level gauge and the external reference level gauge are capacitive level gauges, and the external reference level gauge is matched with a visual scale.

4. The two-component dispensing machine feeding ratio monitoring and alarm device as described in claim 3, characterized in that, The liquid level data collected by the external reference level gauge needs to be manually verified against the data obtained by the matching visual scale. If the deviation between the two exceeds the preset range, the external reference level gauge is calibrated to ensure the accuracy of the external reference level gauge data.

5. A method for monitoring and alarming the feeding ratio of a two-component dispensing machine, based on the two-component dispensing machine feeding ratio monitoring and alarm device according to any one of claims 1-4, characterized in that, include: Input the density parameter of the rubber compound into the data acquisition and analysis module according to its properties, and set the rubber compound ratio and the flow rate of the mixture according to the production process requirements. The information monitoring module collects data on the state of the rubber compound and the operation data of the equipment, and transmits them to the data acquisition and analysis module. The data acquisition and analysis module compares the device operating data with preset thresholds, generates a liquid level abnormality alarm signal, and transmits it to the data push module. The data acquisition and analysis module also calculates the actual output flow rate and actual mixing ratio of the material, compares the actual mixing ratio with the rubber ratio, and generates a ratio abnormality alarm signal if the deviation exceeds the threshold. At the same time, the feedback flow rate is calculated, and compared with the actual output flow rate. If the deviation exceeds the threshold, a flow rate abnormality alarm signal is generated and transmitted to the data push module. The data push module transmits abnormal liquid level alarm signals, abnormal flow rate alarm signals, and abnormal ratio alarm signals to the terminal device to complete the monitoring and alarm process.

6. The method for monitoring and alarming the feeding ratio of a two-component dispensing machine as described in claim 5, characterized in that, The material condition data includes the material temperature in the material storage tank and pipeline collected by a temperature sensor, and the mixed material flow rate at the mixing pipe outlet collected by an online flow meter; the device operation data includes the pressure at the discharge pump outlet and mixing pipe outlet collected by a pressure sensor, and the liquid level data of the material storage tank collected by a level gauge.

7. The method for monitoring and alarming the feeding ratio of a two-component dispensing machine as described in claim 5, characterized in that, The formula for calculating the actual output flow rate of the material is as follows: ;in, This represents the actual output flow rate of the material. This refers to the actual output volume of the material. Liquid level drops The corresponding time, The diameter of the material storage tank. This refers to the height by which the liquid level drops.

8. The method for monitoring and alarming the feeding ratio of a two-component dispensing machine as described in claim 5, characterized in that, The formula for calculating the actual mixing ratio is: ;in, , The output quality of material A and material B are respectively. , These are the actual output flow rates of material A and material B, respectively. , The densities of material A and material B are respectively. The calculation period is specified.

9. The method for monitoring and alarming the feeding ratio of a two-component dispensing machine as described in claim 5, characterized in that, The formula for calculating the feedback flow is: ； ； in, To provide feedback on traffic, This refers to the single-revolution displacement of the gear pump. For the volume of a single tooth valley, This refers to the number of teeth on the gear. This refers to the gear pump speed. This refers to the volumetric efficiency of the gear pump.

10. The method for monitoring and alarming the feeding ratio of a two-component dispensing machine as described in claim 5, characterized in that, Also includes: Based on the comparison between the pressure at the outlet of the discharge pump and the outlet of the mixing pipe in the device operation data and the preset normal pressure, if the pressure exceeds the range, a pressure abnormality alarm signal is generated and transmitted to the data push module.

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