Control method and system for gravure ink production line

Abstract

The invention relates to a gravure ink production line control method and system, and relates to the field of ink production control, and the method comprises the steps: collecting ink parameters, container geometric parameters, a liquid level height value of a conveying device, and device parameters; determining a material supplementing height value according to the device parameters, and determining pigment reference information according to the printing ink parameters; when the liquid level height value is smaller than the material supplementing height value, the pigment liquid in the stirring container is conveyed to a conveying device, a feeding instruction is synchronously output, and the water level height value is collected; determining a water inlet angle and a water inlet height value based on the water level height value and the container geometric parameters; in response to the feeding instruction, controlling the pigment liquid to be injected into the stirring container at a water inlet angle and a water inlet height value, placing a gravity ball to assist stirring, after stirring is completed, recycling the gravity ball to sample pigment to obtain pigment information, and determining supplementing information according to the pigment information and pigment reference information, and supplementing the pigment liquid in the stirring container according to the supplementing information. The method has the effect of saving energy consumption.

Description

Technical Field

[0001] This invention relates to the field of ink production control, and in particular to a control method and system for a gravure ink production line. Background Technology

[0002] A gravure ink production line refers to a specialized equipment system used to produce gravure printing inks. Its core objective is to manufacture ink products that meet the requirements of the gravure printing process.

[0003] Currently in the industry, gravure ink production line equipment scheduling mostly adopts a single-equipment independent start-stop or partial linkage mode, realizing basic control through the equipment system, combined with single-equipment energy-saving technologies such as frequency conversion speed regulation and waste heat recovery.

[0004] The above solution mainly achieves energy saving by linking the start and stop of multiple systems within the equipment. When the ink runs out, the equipment needs to be stopped to readjust the color and refill due to the residue on the walls of the filling container. Frequent start and stop of the conveying equipment will lead to high energy consumption. Summary of the Invention

[0005] To save energy, this invention provides a control method and system for a gravure ink production line.

[0006] In a first aspect, the present invention provides a control method for a gravure ink production line, which adopts the following technical solution: A control method for a gravure ink production line includes: Collect the ink parameters, container geometry parameters, preset liquid level height value and device parameters of the ink to be processed; The feeding height value of the conveying device is determined based on the device parameters, and the pigment reference information is determined based on the ink parameters. When the liquid level is lower than the feeding height, the pigment liquid in the mixing container is transported to the conveying device, the feeding command is output simultaneously, and the water level in the mixing container is collected. The inlet angle and inlet height are determined based on the water level and container geometry. In response to the feeding command, the pigment liquid is injected into the mixing container at the inlet angle and inlet height, and a preset gravity ball is placed to assist in the mixing. After the mixing is completed, the gravity ball is retrieved to sample the pigment to obtain pigment information. Based on the pigment information and pigment reference information, the feeding information is determined and the pigment liquid in the mixing container is fed with the feeding information.

[0007] By adopting the above technical solution, after collecting ink parameters and container geometric parameters, the replenishment height and pigment reference are automatically calculated. When the liquid level is lower than the threshold, replenishment is triggered and the water inlet angle and height are calculated simultaneously. With the assistance of gravity ball, electric stirring is achieved, saving energy. Subsequently, the ball is recovered and sampled for comparison to obtain replenishment information, thereby quickly determining the replenishment to improve the batching efficiency.

[0008] Optionally, the steps of determining the inlet angle and inlet height based on the water level and container geometry include: The viscosity of the pigment solution and the stirring time are determined based on the ink parameters; Determine the container diameter based on the container's geometric parameters; The stirring force should be matched according to the viscosity of the pigment solution; Calculate the radius of curvature of the liquid surface based on the water level and container diameter; The water inlet angle is matched according to the radius of curvature and the viscosity of the pigment liquid; The water inlet height is determined based on the stirring time and stirring intensity.

[0009] By adopting the above technical solution, the water inlet angle is matched according to the ink viscosity and the radius of curvature of the liquid surface, and the water inlet height is determined by combining the stirring time and force, so that the pigment liquid is injected tangentially along the wall surface, thereby forming a vortex, reducing splashing and bubbles, improving mixing uniformity and shortening the stirring cycle.

[0010] Optionally, after being injected into the mixing container, the following may also be included: When a vortex is formed inside the mixing container, the vortex kinetic energy received by the preset stirring rod is collected simultaneously. The starting energy is determined based on the pigment reference information, and the vortex kinetic energy is updated to determine the stirring power when it is less than the starting energy. In response to the feeding command, the stirring rod is controlled by the stirring power to stir. Stirring ends when the vortex kinetic energy is equal to the start-up energy or the vortex kinetic energy is zero.

[0011] By adopting the above technical solution, the kinetic energy of the stirring rod is collected in real time when the vortex is formed. The stirring power is dynamically updated after the energy consumption is reduced by kinetic energy recovery and compared with the start-up energy. Stirring stops when the kinetic energy is zero or equal to the threshold, while ensuring stirring efficiency.

[0012] Optionally, the steps for collecting the vortex kinetic energy of a preset stirring rod include: Real-time vortex velocity and shear stress at the vortex center were collected; When the shear stress is not zero, an unlock command is output; In response to the unlock command, the preset stirring rod is controlled to collect kinetic energy. The rotation radius and angular velocity of the vortex are determined based on the vortex velocity and the preset stirring radius. The energy loss value of the vortex is determined based on the shear stress and the rotational angular velocity of the vortex. The initial value of the vortex kinetic energy is calculated based on the vortex's rotation radius and energy loss value; The vortex kinetic energy is determined based on the initial value of the vortex kinetic energy and the stirring power.

[0013] By adopting the above technical solution, the rotation radius and energy loss are calculated based on the vortex velocity and shear stress. At the same time, kinetic energy is recovered to achieve energy saving. The initial value of vortex kinetic energy is obtained, and then combined with the stirring power to obtain the real-time kinetic energy. This provides a quantitative basis for power adjustment and ensures that the stirring process is always in the optimal energy range.

[0014] Optionally, methods for recovering the gravity ball for pigment sampling include: Collect the liquid level fluctuation value of the pigment liquid, the position of the gravity ball, and the pressure parameters at the bottom of the container; The relative distance between the gravity sphere and the container outlet, and the recovery path, are determined based on the position of the gravity sphere and the container geometry. Match fluctuation thresholds based on water level and pressure parameters; Until the liquid level fluctuation value is less than the fluctuation threshold, the preset recovery device will recover the gravity ball along the recovery path and move it to the preset sampling area to sample the pigment on the surface. After sampling, return the sample to its pre-positioned location within the mixing container to complete the gravity ball recovery and pigment sampling.

[0015] By adopting the above technical solution, the liquid level fluctuation and container pressure are monitored. After the fluctuation is lower than the threshold, the gravity ball is moved to the sampling area along the recovery path to complete the surface pigment collection. Then the ball is reset, realizing interference-free online sampling and shortening the test waiting time.

[0016] Optional, also includes: Collect data on the adhesion to the inner wall of the mixing container and the liquid level fluctuation value; The attachment threshold is matched based on the container geometry parameters; The thickness of the adhesion layer and the vibration frequency are determined based on the adhesion conditions and container geometry. Based on the container geometry parameters, the region where the adhesion layer thickness is greater than the adhesion threshold is determined, and this region is defined as the excessively thick region. The required number of balls is determined based on the excessively thick region; The window time point for selecting the lowest point of liquid level is determined based on the water level height and liquid level fluctuation value. In response to the cleaning command, the preset cleaning device is controlled by the vibration frequency to vibrate the outer wall of the mixing container, and gravity balls are released according to the number of small balls and the window time point to clean the attached pigment.

[0017] By adopting the above technical solution, taking into account the thickness of the adhesion layer and the window time point, a quantitative amount of gravity balls are simultaneously released on the outer wall at a matching vibration frequency. The balls roll and strike areas with excessive thickness, achieving efficient peeling, reducing manual intervention, keeping the inner wall of the container clean, and extending the equipment operating cycle.

[0018] Optional methods for collecting adhesion data include: Collect the sound waves along the trajectory of a falling gravity ball; Wave images are extracted from the orbital acoustic waves to identify wave points; Determine the fluctuation thickness based on the fluctuation point; The attachment location is determined based on the wave image and container geometry. The adhesion status is determined based on the adhesion location and fluctuating thickness.

[0019] By adopting the above technical solution, the trajectory acoustic wave generated by the falling gravity ball is used to invert the wave image, accurately locate the attachment point and thickness, and improve the real-time performance and accuracy of attachment detection.

[0020] Optionally, cleaning the attached pigment also includes: The natural frequency of the gravity ball during rolling and the damping parameters of the preset cleaning device are collected. Determine the persistence threshold based on adhesion conditions and container geometry; Based on the container's geometric parameters and damping parameters, the region where the adhesion layer thickness is greater than the stubbornness threshold is determined and defined as the stubborn region; The frequency coefficient is determined based on the vibration frequency and the natural frequency; The resonance timing is determined based on the frequency coefficient and the stubborn region, and the window time point is updated with the resonance timing. In response to the cleaning command, the vibration frequency is adjusted in real time using a frequency coefficient to control the cleaning device to vibrate the outer wall of the mixing container, and gravity balls are released according to the number of small balls and the window time point to complete the cleaning.

[0021] By adopting the above technical solution, the vibration frequency is dynamically adjusted with a frequency coefficient to resonate with the natural frequency of the sphere, thereby increasing the cleaning depth. Combined with the identification of stubborn areas, the sphere is controlled at the right time to achieve resonance cleaning of stubborn attachments and reduce the residue rate.

[0022] Optionally, the steps for launching the gravity ball may also include: The resistance value of the gravity sphere inside the track is determined based on the acoustic waves of the track. Match the safety threshold based on the number of balls; When the resistance value exceeds the safety threshold, the continuous launch of a single ball is suspended and the launch of multiple balls is switched to synchronous launch. Determine the track cross-sectional dimensions based on the container's geometric parameters; The number of balls to be launched simultaneously is calculated based on the track cross-section dimensions and adhesion conditions; Control the gravity ball to launch and release the balls synchronously to complete the clearing.

[0023] By adopting the above technical solution, when the track resistance exceeds the safety threshold, it automatically switches to the multi-ball synchronous launch mode. The number of synchronous balls is calculated based on the cross-sectional size and adhesion condition, and they are released at once to form an impact wave surface, which quickly removes the thick adhesion, shortens the time for a single cleaning, and ensures the continuous and efficient operation of the production line.

[0024] Secondly, this application provides a control system for a gravure ink production line, which adopts the following technical solution: A control system for a gravure ink production line includes: The acquisition module is used to acquire ink parameters, container geometric parameters, liquid level height values, and device parameter water level height values. The memory is used to store the program that implements the control method of any gravure ink production line; The processor loads and executes programs from memory.

[0025] By adopting the above technical solution, after the acquisition module collects ink parameters and container geometric parameters, the processor automatically calculates the replenishment height and pigment reference. When the liquid level is lower than the threshold, replenishment is triggered and the water inlet angle and height are calculated simultaneously. With the assistance of gravity ball, electric stirring is achieved, saving energy. Subsequently, the ball is recovered, sampled and compared to obtain replenishment information and stored in the memory, thereby quickly determining replenishment to improve the batching efficiency.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. By using gravity balls to assist in achieving electricity-free stirring, energy consumption is saved. Subsequently, the ball is recovered and sampled for comparison to obtain feeding information, thereby quickly determining the feeding and improving the batching efficiency; 2. Energy is collected through vortexes, and kinetic energy is recovered to achieve energy-saving effects; 3. By adjusting the vibration frequency and resonating with the natural frequency of the ball, the cleaning depth is increased. Combined with the identification of stubborn areas, the ball is controlled at the right time to achieve resonance cleaning of stubborn attachments and reduce the residue rate. Attached Figure Description

[0027] Figure 1 This is a flowchart of a method for controlling a gravure ink production line according to an embodiment of the present invention; Figure 2 This is a flowchart of the method for collecting vortex kinetic energy according to an embodiment of the present invention; Figure 3 This is a schematic diagram of an embodiment of the present invention. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0029] This application discloses a control method for a gravure ink production line, wherein pigment is the core coloring component, pigment liquid is a dispersed intermediate material of pigment, and ink is a finished product after pigment liquid (or pigment) is compounded with various additives.

[0030] Reference Figure 1 A method for controlling a gravure ink production line includes the following steps: S100: Collects the ink parameters, container geometry parameters, preset liquid level height value of the conveying device, and device parameters of the ink to be processed.

[0031] Ink parameters refer to the physical properties of the ink to be produced, such as viscosity, density, and pigment content.

[0032] Container geometry parameters refer to the dimensional data of the mixing container, such as its inner diameter, height, and bottom shape.

[0033] The liquid level height value refers to the real-time height of the pigment liquid surface in the current conveying device.

[0034] Device parameters refer to the specifications of the conveying device, such as rated flow rate, diameter, and material.

[0035] The conveying device refers to the device that fills ink with ink output from the mixing container. It consists of a transfer pump, a liquid level sensor, and a conveying container, etc. This is set in advance by technicians according to the actual situation and will not be described in detail here.

[0036] Ink parameters, container geometric parameters, liquid level height values, and device parameters are all known input quantities. The viscosity, density, and pigment content of the ink to be produced are obtained through physical property testing equipment, which are the ink parameters. The inner diameter, height, and bottom shape of the mixing container are obtained through dimensional measuring tools, which are the container geometric parameters. The pigment liquid level height in the conveying device is collected in real time by a liquid level sensor, which is the liquid level height value. The rated flow rate, diameter, and material are extracted from the design specifications of the conveying device, which are the device parameters.

[0037] S101: Determine the feeding height value of the conveying device based on the device parameters, and determine the pigment reference information based on the ink parameters.

[0038] The replenishment height value refers to the critical liquid level height that triggers automatic replenishment.

[0039] Pigment reference information refers to the information of the pigments used in the formulation of inks, such as physical properties data like viscosity, density, and pigment content.

[0040] Based on the device parameters, the critical liquid level value that triggers automatic material replenishment is set, which is the material replenishment height value; based on the ink parameters, the standard indicators such as viscosity, density, and pigment content of the target finished ink are defined, which is the pigment reference information.

[0041] S102: When the liquid level is lower than the feeding height, the pigment liquid in the mixing container is transported to the conveying device, the feeding command is output simultaneously, and the water level in the mixing container is collected.

[0042] The feeding command is a signal issued by the system to inject materials.

[0043] The water level height value refers to the height of the liquid level of the ink to be replenished in the mixing container, which is collected by a liquid level sensor.

[0044] The stirring container refers to the container used to stir the ink. The inner wall has a track for the gravity ball and the ink to roll, as well as a liquid level sensor. This is preset by technicians according to the actual situation and will not be described in detail here.

[0045] When the liquid level is lower than the replenishment height, it indicates that the pigment in the conveying device is insufficient and needs to be replenished. Therefore, a feeding command is output, and the water level in the mixing container is collected.

[0046] S103: Determine the inlet angle and inlet height based on the water level and container geometry.

[0047] The water inlet angle refers to the angle between the nozzle and the horizontal plane when new pigment flows into the mixing container, in order to reduce splashing.

[0048] The water inlet height value refers to the vertical height of the nozzle outlet from the liquid surface.

[0049] The specific methods are described in steps S200 to S205, and will not be repeated here.

[0050] S104: In response to the feeding command, control the pigment liquid to be injected into the mixing container at the inlet angle and inlet height, and place a preset gravity ball to assist in stirring. After stirring is completed, retrieve the gravity ball to sample the pigment to obtain pigment information, and determine the feeding information based on the pigment information and pigment reference information, and feed the pigment liquid in the mixing container with the feeding information.

[0051] Gravity spheres are spherical counterweights with clean surfaces and a density greater than that of the pigment liquid. They are used to enhance eddies and shearing. These are preset by technicians according to actual conditions and will not be elaborated here.

[0052] Pigment information refers to the color information of the pigments in the printing ink.

[0053] The replenishment information refers to a list of the types, quality, and injection timing of the pigments that need to be replenished.

[0054] Upon receiving a feeding instruction, the system controls the injection of pigment liquid into the mixing container at the appropriate inlet angle and height, and places a gravity ball to assist in stirring, thereby creating a vortex. The gravity ball is then retrieved and placed on a pre-set sampling paper. Pigment samples are taken using a camera to obtain pigment information. Based on the pigment baseline information and the measured pigment information, a list of pigment types, qualities, and time sequences to be replenished is generated, which serves as the feeding information. The pigment liquid in the mixing container is then replenished using this feeding information.

[0055] In this embodiment, stirring is achieved by creating a vortex in the water flow, combined with the assistance of a gravity ball and a stirring rod to ensure the stirring effect. The stirring is aided by the potential energy carried by the gravity ball as it falls along the track. After being collected, sampled, cleaned, and reused, the stirring rod achieves stirring without electricity by collecting and releasing the energy of the vortex.

[0056] The steps for determining the inlet angle and inlet height based on the water level and container geometry include the following: S200: Determine the pigment liquid viscosity and stirring time based on ink parameters.

[0057] The viscosity of a pigment liquid refers to the resistance to its flow.

[0058] Stirring time refers to the time required for the ink to be processed to be stirred completely.

[0059] The flow resistance of the pigment liquid is directly extracted from the ink parameters, which is the viscosity of the pigment liquid. The stirring time is determined according to the ink formula and process requirements.

[0060] S201: Determine the container diameter based on the container's geometric parameters.

[0061] The container diameter refers to the diameter of the inner cavity of the mixing container.

[0062] The container diameter of the stirring vessel is selected based on the container geometry parameters and used as the key dimension for subsequent liquid level calculations.

[0063] S202: Match the stirring force according to the viscosity of the pigment liquid.

[0064] Stirring force refers to the magnitude of the shear torque applied to the pigment liquid by the stirring rod, which is positively correlated with viscosity.

[0065] The higher the viscosity of the pigment liquid, the greater the stirring force. The stirring force is obtained by inputting the viscosity of the pigment liquid into a preset stirring force linear chart. The stirring force linear chart is a linear chart preset by technicians according to the actual situation. The stirring force linear chart contains the correlation between the viscosity of the pigment liquid and the stirring force. The actual correlation is preset by technicians according to the actual situation.

[0066] S203: Calculate the radius of curvature of the liquid surface based on the water level and container diameter.

[0067] The radius of curvature refers to the radius of the circular arc indentation at the center of the rotating liquid surface, and is used to calculate the depth of the eddy.

[0068] Substituting the water level and container diameter into the rotating fluid dynamics formula, the radius of the arc of the concave center of the liquid surface during stirring is calculated, which is the radius of curvature. This is used to quantify the eddy depth. The rotating fluid dynamics formula is common knowledge to those skilled in the art and will not be elaborated here.

[0069] S204: Match the water inlet angle according to the radius of curvature and the viscosity of the pigment liquid.

[0070] The water inlet angle is obtained by inputting the radius of curvature and pigment viscosity into a preset linear chart of water inlet angle. The linear chart of water inlet angle is a linear chart preset by technicians according to the actual situation. The linear chart of water inlet angle contains the correlation between the radius of curvature and pigment viscosity and the water inlet angle. The actual correlation is preset by technicians according to the actual situation.

[0071] S205: Determine the water inlet height based on the stirring time and stirring intensity.

[0072] The longer the stirring time and the greater the stirring force, the greater the water inlet height. The water inlet height is obtained by inputting the stirring time and stirring force into a preset water inlet height linear chart. The water inlet height linear chart is a linear chart preset by technicians according to the actual situation. The water inlet height linear chart contains the correlation between stirring time and stirring force and water inlet height. The actual correlation is preset by technicians according to the actual situation.

[0073] After pouring into the mixing container, the following steps are also included: S300: When a vortex is formed inside the mixing container, the vortex kinetic energy received by the preset stirring rod is collected simultaneously.

[0074] Vortex kinetic energy refers to the elastic deformation energy generated by the stirring rod due to the impact of the vortex. The energy of the water vortex rotation is collected by an electromagnetic generator and stored in a preset small battery. The small battery powers the electromagnetic generator, thereby driving the stirring rod to rotate.

[0075] When a vortex forms inside the mixing container, it indicates that mixing has begun, thus preparing to collect the kinetic energy of rotation. Simultaneously, the vortex kinetic energy received by the stirring rod is collected, and the vortex kinetic energy is obtained through the collection of an electromagnetic generator.

[0076] S301: Determine the start-up energy based on the pigment reference information, and update the vortex kinetic energy to determine the stirring power when the vortex kinetic energy is less than the start-up energy.

[0077] The start-up energy refers to the energy threshold used to determine whether there is a stirring effect.

[0078] Stirring power refers to the rotational power required for the stirring rod to rotate and maintain the stirring effect.

[0079] The start-up energy is obtained by inputting the pigment reference information into a preset start-up energy linear chart. The start-up energy linear chart is a linear chart preset by technicians according to the actual situation. The start-up energy linear chart contains the correspondence between the pigment reference information and the start-up energy. The actual correspondence is preset by technicians according to the actual situation.

[0080] The vortex kinetic energy is substituted into the physical formula to determine the stirring power. The formula is common knowledge to those skilled in the art and will not be elaborated here.

[0081] S302: In response to the feeding command, the stirring rod is controlled by the stirring power to stir. When the vortex kinetic energy is equal to the starting energy or the vortex kinetic energy is zero, the stirring ends.

[0082] Upon receiving a feeding command, the stirring rod is controlled by the stirring power to stir. When the vortex kinetic energy equals the start-up energy or the vortex kinetic energy is zero, it indicates that the stirring effect has met the standard or the vortex has disappeared, and stirring is stopped.

[0083] Reference Figure 2 The steps for collecting the vortex kinetic energy of the preset stirring rod include the following: S400: Collects real-time vortex velocity and shear stress at the vortex center.

[0084] The vortex velocity refers to the tangential velocity at the center point of the liquid surface.

[0085] Shear stress refers to the tangential force exerted by the fluid on a unit area of ​​the stirring rod surface.

[0086] The vortex velocity and shear stress are collected by sensors on the generator on the stirring rod. The sensors on the generator are preset by technicians according to the actual situation, and will not be described in detail here.

[0087] S401: When the shear stress is not zero, output the unlock command.

[0088] The unlock command is a signal that allows the stirring rod to rotate freely and collect kinetic energy.

[0089] When the shear stress is not zero, it indicates the presence of vortices or water flow, which allows for energy recovery, thus triggering the output of an unlock command.

[0090] S402: In response to the unlock command, control the preset stirring rod to perform kinetic energy conversion and collection.

[0091] Upon receiving the unlock command, the generator on the stirring rod is controlled to collect and convert kinetic energy.

[0092] S403: Determine the vortex's rotation radius and angular velocity based on the vortex velocity and the preset stirring radius.

[0093] The stirring radius refers to half the length of the stirring rod, which is preset by technicians based on actual conditions.

[0094] The rotation radius refers to the radius of the vortex and is used to determine the initial value of the subsequent vortex kinetic energy.

[0095] Rotational angular velocity refers to the magnitude of the angular velocity of the vortex's rotation, and is used to determine the subsequent energy loss value.

[0096] The stirring radius determines the basic range of action of the fluid, and the vortex velocity reflects the actual flow intensity of the vortex. By using the proportional relationship between the stirring radius and the vortex radius derived based on the conservation of momentum, the effective range covered by the vortex, i.e., the rotation radius, can be determined first. Then, according to the physical formula ω=v / r (where ω is the rotation angular velocity, v is the vortex velocity, and r is the rotation radius), the rotation angular velocity of the vortex can be calculated by substituting the data.

[0097] S404: Determine the energy loss value of the vortex based on the shear stress and the rotational angular velocity of the vortex.

[0098] Energy loss value refers to the energy lost when the stirring rod is rotated.

[0099] The frictional resistance of the fluid to the stirring rod is determined based on the shear stress, and then the linear velocity of the stirring rod is calculated by combining the rotational angular velocity. Finally, the energy loss value is calculated by "energy loss value = frictional resistance × linear velocity".

[0100] S405: The initial value of vortex kinetic energy is calculated based on the vortex's rotation radius and energy loss value.

[0101] The initial value of vortex kinetic energy refers to the initial kinetic energy of the vortex when it begins to rotate.

[0102] The radius of rotation affects the coverage area of ​​the vortex and the moment of inertia of the fluid. The larger the radius of rotation, the more fluid mass participates in the rotation, and the greater the moment of inertia. The energy loss value is the energy loss generated during the rotation of the stirring rod driven by the vortex, which needs to be considered in the kinetic energy calculation. First, the vortex kinetic energy under ideal conditions is calculated; then, the initial kinetic energy of the vortex rotation is calculated by using the formula: "Initial vortex kinetic energy = Ideal vortex kinetic energy - Energy loss value".

[0103] S406: Determine the vortex kinetic energy based on the initial value of the vortex kinetic energy and the stirring power.

[0104] First, the stirring power is converted into the effective energy input per unit time, then the initial value of vortex kinetic energy is added, and finally the real-time vortex kinetic energy is calculated through the energy balance model (real-time vortex kinetic energy = initial value of vortex kinetic energy + stirring power × time × conversion coefficient). This provides data support for the start and stop control of the stirring process. The conversion coefficient is preset by the technicians according to the actual situation and will not be elaborated here.

[0105] The method for recovering gravity balls to sample pigments includes the following steps: S500: Collects the liquid level fluctuation value of the pigment liquid, the position of the gravity ball, and the pressure parameters at the bottom of the container.

[0106] Liquid level fluctuation value refers to the real-time standard deviation of liquid level height, used to quantify the intensity of fluctuation.

[0107] The position of the gravity sphere refers to its three-dimensional coordinates at the bottom of the container.

[0108] The pressure parameter refers to the instantaneous pressure measured by the pressure sensor at the bottom of the container; this is a variable value.

[0109] The liquid level sensor captures the liquid level height data of the pigment liquid in real time to obtain the liquid level fluctuation value; a piezoelectric pressure sensor is installed at the bottom of the container to monitor the pressure of the pigment liquid on the bottom of the container in real time and record the dynamically changing pressure parameters. The position of the gravity ball is determined by a preset ultrasonic imager, which provides the basic support for subsequent steps.

[0110] S501: Determine the relative distance between the gravity ball and the container outlet, and the recovery path, based on the position of the gravity ball and the container geometry.

[0111] Relative distance refers to the straight-line distance from the gravity sphere to the center of the container outlet.

[0112] The recovery path refers to the collision-free trajectory of the gravity ball as it moves from its current position to the discharge port.

[0113] The three-dimensional coordinates of the container outlet are extracted from the container's geometric parameters. The straight-line distance between the current three-dimensional coordinates of the gravity ball and the container outlet coordinates is calculated using the distance formula between two points in space, i.e., the relative distance between the two. Based on this relative distance, combined with the inner wall contour, track dimensions, and obstacle distribution in the container's geometric parameters, a path planning algorithm is used to avoid the container wall and internal structure, planning the shortest collision-free trajectory from the gravity ball's position to the container outlet. This forms a recovery path that adapts to the action of the magnetic retrieval device, ensuring that the gravity ball recovery process is smooth and does not interfere with the state of the pigment.

[0114] S502: Match fluctuation thresholds based on water level and pressure parameters.

[0115] The fluctuation threshold refers to the upper limit of liquid surface fluctuation at which the recovery of the gravity ball can begin.

[0116] The fluctuation threshold is obtained by inputting the water level and pressure parameters into a preset fluctuation threshold linear chart. The fluctuation threshold linear chart is a linear chart preset by technicians according to the actual situation. The fluctuation threshold linear chart contains the correspondence between the water level and pressure parameters and the fluctuation threshold. The actual correspondence is preset by technicians according to the actual situation.

[0117] S503: Until the liquid level fluctuation value is less than the fluctuation threshold, control the preset recovery device to recover the gravity ball along the recovery path and transfer it to the preset sampling area to sample the pigment on the surface.

[0118] A recycling device refers to a mechanical mechanism that uses magnetic attraction to grab and transfer a gravity ball, such as a mechanical claw equipped with magnets.

[0119] The sampling area refers to the designated station for scraping or rinsing the pigment attached to the surface of the gravity ball, which is an S-shaped track with multiple layers of sampling paper.

[0120] The liquid level fluctuation value is kept below the fluctuation threshold, indicating that the liquid level is stable. The recovery device is then controlled to recover the gravity ball along the recovery path and move it to the sampling area. The gravity ball rolls down and leaves a mark on the sampling paper to sample the pigment on the surface of the gravity ball.

[0121] S504: After sampling, return the sample to its pre-positioned location within the mixing container to complete the gravity ball recovery and pigment sampling.

[0122] The storage location refers to the initial docking point of the gravity ball inside the mixing container. This is set in advance by technicians based on the actual situation and will not be elaborated here.

[0123] After sampling, return the sample to its storage location in the mixing container for future use, thus completing the gravity ball recovery and pigment sampling.

[0124] It also includes the following steps: S600: Collects the adhesion status and liquid level fluctuation value on the inner wall of the mixing container.

[0125] The adhesion condition refers to the thickness distribution of the pigment layer on the sidewall.

[0126] The method for adhesion is described in steps S700 to S704, and will not be repeated here.

[0127] The liquid level fluctuation value is the same as that of S500.

[0128] S601: Match the attachment threshold based on the container geometry parameters.

[0129] The adhesion threshold refers to the minimum wall thickness required for cleaning.

[0130] The attachment threshold is obtained by inputting the container geometry parameters into a preset attachment threshold linear chart. The attachment threshold linear chart is a linear chart preset by technicians according to the actual situation. The attachment threshold linear chart contains the correspondence between the container geometry parameters and the attachment threshold. The actual correspondence is preset by technicians according to the actual situation.

[0131] S602: Determine the adhesion layer thickness and vibration frequency based on the adhesion conditions and container geometry.

[0132] The thickness of the adhesive layer refers to the thickness of the ink adhering inside the mixing container.

[0133] Vibration frequency refers to the frequency at which the cleaning device strikes the wall surface.

[0134] Regarding the coating thickness, the adhesion condition already includes the preliminary thickness distribution characteristics of the pigment layer. Combined with structural information such as wall curvature and track groove size in the container geometry parameters, the thickness measurement deviation in different areas (such as straight walls and track grooves) can be calibrated (for example, the local accumulation thickness in the track groove needs to be corrected by combining the groove width). Finally, the coating thickness of each area is quantified to obtain a uniform standard. Regarding the vibration frequency, the vibration frequency is obtained by inputting the coating thickness into a preset vibration frequency linear chart. The vibration frequency linear chart is a linear chart preset by technicians according to the actual situation. The vibration frequency linear chart contains the correlation between the coating thickness and the vibration frequency. The actual correlation is preset by technicians according to the actual situation.

[0135] S603: Determine the region where the thickness of the adhesion layer is greater than the adhesion threshold based on the container geometry parameters, and define this region as an excessively thick region.

[0136] Excessively thick areas refer to localized areas on the wall surface where the pigment layer exceeds the adhesion threshold.

[0137] Based on the container's geometric parameters, regions where the adhesion layer thickness exceeds the adhesion threshold are defined as excessively thick regions, in order to determine the required number of balls later.

[0138] S604: Determine the required number of balls based on the excessively thick region.

[0139] The number of small balls refers to the number of gravity balls used to impact the wall.

[0140] The number of balls is obtained by inputting the overly thick area into a preset linear chart of the number of balls. The linear chart of the number of balls is a linear chart preset by technicians according to the actual situation. The linear chart of the number of balls contains the correspondence between the overly thick area and the number of balls. The actual correspondence is preset by technicians according to the actual situation.

[0141] S605: Determine the window time point for selecting the lowest point of liquid level based on the water level height and liquid level fluctuation value.

[0142] The window time point refers to the cleaning opportunity when the liquid level is lowest and the wall surface is best exposed.

[0143] By identifying the dynamic process of the liquid level in the descending phase through water level height, the range of change in the continuously decreasing height value is locked; then, the liquid level fluctuation value within the range is compared synchronously, and the time period when the fluctuation value is less than the preset stable threshold is selected as the window time point. At this time, the disturbance in the liquid level descent process is minimal, and then the moment when the water level height drops to the lowest point in the stage is located within this stable period.

[0144] S606: In response to a cleaning command, a preset cleaning device is controlled by a vibration frequency to vibrate the outer wall of the mixing container, and gravity balls are released according to the number of small balls and the window time point to clean the attached pigment.

[0145] Cleaning devices refer to vibratory and impact mechanisms installed on the outer wall of a mixing container, such as vibrators.

[0146] A cleanup command is a signal issued by the system to initiate wall cleanup, such as a signal issued by software.

[0147] Upon receiving a cleaning instruction, the system controls a preset cleaning device to vibrate the outer wall of the mixing container using a vibration frequency, and releases gravity balls according to the number of small balls and the window time points to clean the attached pigment, thereby performing the cleaning process.

[0148] The method for collecting data on adhesion includes the following steps: S700: Collects the acoustic waves of a falling gravity ball.

[0149] Track sound waves refer to the sound signals generated when a gravity ball hits the track as it falls along the track.

[0150] The sound of the gravity ball falling is collected by a pre-set microphone to obtain the track sound wave. The microphone is pre-set on the outer wall of the container to pick up the sound of the gravity ball falling along the track.

[0151] S701: Extract wave images based on track acoustic waves to identify wave points.

[0152] Wave imaging refers to the conversion of acoustic wave signals into time-domain and amplitude images.

[0153] Fluctuation points refer to pixels in an image that exhibit abrupt changes in amplitude, and are used to determine the location and condition of ink adhesion.

[0154] The collected acoustic signals are preprocessed and converted into a two-dimensional wave image with time and amplitude fluctuations (the horizontal axis represents time and the vertical axis represents acoustic amplitude, which intuitively presents the dynamic changes of the impact signal). Then, the image recognition algorithm is used to filter out the pixels in the image where the amplitude suddenly increases or decreases, i.e., the fluctuation points. These fluctuation points correspond to the signal abrupt change when the gravity ball hits the pigment adhesion area, which provides the core feature basis for subsequent determination of the adhesion location and fluctuation thickness.

[0155] S702: Determine the fluctuation thickness based on the fluctuation point.

[0156] Fluctuation thickness refers to the uneven thickness of ink adhering to a local area inside the stirring container.

[0157] The effect of pigment adhesion on impact is reflected by the intensity of signal abrupt changes—the thicker the pigment adhesion, the stronger the buffering effect when the gravity ball impacts the track, and the greater the amplitude abrupt change in sound wave amplitude (the difference in amplitude between the abrupt change and the unattached area). First, using a pre-set calibration curve, the amplitude abrupt change difference at each fluctuation point (i.e., the difference in sound wave amplitude between the fluctuation point and the adjacent unattached area) is extracted. This difference is then substituted into the calibration curve to deduce the local adhesion thickness at the corresponding location, i.e., the fluctuation thickness. The calibration curve is pre-set by technicians based on actual conditions and will not be elaborated here.

[0158] S703: Determine the attachment location based on the wave pattern and container geometry.

[0159] The attachment location refers to the specific coordinates of the thickening of the pigment layer on the inner wall surface of the mixing container.

[0160] The time sequence of the acoustic signals extracted from the wave image corresponds one-to-one with the track path. The occurrence time of the wave point can be mapped to the moment when the gravity ball reaches a certain position on the track. Then, the three-dimensional orientation of the track (starting point, curvature, coordinates of each segment), the relative position of the sensor and the track, and the three-dimensional coordinate system with the center of the bottom of the container as the origin are obtained from the container's geometric parameters. Through the mapping model of time and track position (derived from the rolling speed of the gravity ball and the time sequence of the wave points, i.e., the position of the ball on the track at each time point), the time sequence information of the wave points is converted into the relative distance on the track. Then, combined with the absolute coordinates of the track in the container's geometric parameters, i.e. the attachment position, the positioning is ensured to accurately match the container structure.

[0161] S704: Determine the adhesion status based on the adhesion location and fluctuating thickness.

[0162] The three-dimensional coordinates of each attachment location are correlated with the corresponding fluctuating thickness to form a discrete set of coordinates and thickness. Then, combined with the wall partitions in the container geometry parameters (such as straight wall sections, track grooves, and corners), the data set is classified into regions, and the average thickness, maximum thickness, and standard deviation of thickness distribution of each region are statistically analyzed. Finally, the thickness characteristics and spatial distribution patterns of each region are integrated to comprehensively reflect the attachment status of the pigment layer distribution on the sidewall. This provides a core basis for subsequent identification of excessively thick and stubborn regions and optimization of cleaning parameters.

[0163] Cleaning the attached pigment also includes the following steps: S800: Collects the natural frequency of the gravity ball during rolling and the preset damping parameters of the cleaning device.

[0164] The natural frequency refers to the resonant frequency of the gravitational sphere and the track, which is related to the mass of the sphere and the stiffness of the track.

[0165] The damping parameter refers to the resistance coefficient of the cleaning device, which is used to determine the damping effect of ink adhesion on the vibration frequency.

[0166] The natural frequency is pre-input into the system by technicians based on the actual situation, and the reaction force during vibration is obtained through a cleaning device.

[0167] S801: Determine the stubbornness threshold based on the adhesion status and container geometry.

[0168] The persistence threshold refers to the minimum thickness that is considered to be persistent adhesion.

[0169] The stubborn threshold is obtained by inputting the adhesion status and container geometry parameters into a preset stubborn threshold linear chart. The stubborn threshold linear chart is a linear chart preset by technicians according to the actual situation. The stubborn threshold linear chart contains the correspondence between the adhesion status and container geometry parameters and the stubborn threshold. The actual correspondence is preset by technicians according to the actual situation.

[0170] S802: Based on the container's geometric parameters and damping parameters, the region where the adhesion layer thickness is greater than the stubbornness threshold is determined and defined as the stubborn region.

[0171] Stubborn areas refer to areas where thick layers of adhesion cannot be removed by conventional vibration.

[0172] Based on the container geometry and damping parameters, the region in the mixing container where the adhesion layer thickness is greater than the stubbornness threshold is defined as the stubborn region, in order to determine the required number of balls later.

[0173] S803: Determine the frequency coefficient based on the vibration frequency and the natural frequency.

[0174] The frequency coefficient refers to the ratio of the vibration frequency to the natural frequency, and is used to linearly increase the vibration frequency.

[0175] The ratio obtained by dividing the natural frequency by the vibration frequency, and then dividing the ratio by time, is the frequency coefficient.

[0176] S804: Determines the resonance timing based on the frequency coefficient and the stubborn region, and updates the window time point with the resonance timing.

[0177] The resonance timing refers to the optimal time to initiate resonance cleansing.

[0178] The frequency coefficient provides a frequency reference for resonance, and the stubborn region determines the target location of resonance. When the vibration frequency matches the natural frequency, the ball rolls into the stubborn region. This point in time is the resonance moment, which enables concentrated energy transfer to efficiently peel off stubborn adhesions.

[0179] S805: In response to the cleaning command, the vibration frequency is adjusted in real time with a frequency coefficient to control the cleaning device to vibrate the outer wall of the mixing container, and gravity balls are released according to the number of small balls and the window time point to complete the cleaning.

[0180] Upon receiving a cleaning instruction, the vibration frequency of the cleaning device is adjusted in real time using a frequency coefficient to vibrate the outer wall of the mixing container, causing the vibration frequency to increase linearly. Gravity balls are then released based on the number of small balls and the window time point to complete the cleaning.

[0181] The steps for launching the gravity ball also include the following: S900: Determine the resistance value of the gravity sphere inside the track based on the track acoustic waves.

[0182] The resistance value refers to the sum of frictional and collision resistance experienced by the gravity ball in the track, which is calculated from the amplitude of the sound waves. This is common knowledge to those skilled in the art and will not be elaborated here.

[0183] S901: Match the safety threshold based on the number of balls.

[0184] The safety threshold refers to the maximum allowable resistance value; if this value is exceeded, the transmission mode must be switched.

[0185] The safety threshold is obtained by inputting the number of balls into a preset safety threshold linear chart. The safety threshold linear chart is a linear chart that is preset by technicians according to the actual situation. The safety threshold linear chart contains the correspondence between the number of balls and the safety threshold. The actual correspondence is preset by technicians according to the actual situation.

[0186] S902: When the passage resistance value exceeds the safety threshold, pause continuous single-ball launch and switch to multi-ball synchronous launch.

[0187] Single-ball continuous launch refers to releasing gravity balls one by one.

[0188] Multi-ball simultaneous launch refers to releasing multiple gravity balls at once, creating a multi-ball impact.

[0189] When the resistance value exceeds the safety threshold, it means that a single ball cannot clear the obstruction. Continuous single-ball launches are paused, and multi-ball synchronous launches are switched.

[0190] S903: Determine the track cross-sectional dimensions based on the container's geometric parameters.

[0191] The track cross-sectional dimensions refer to the width and height of the track's inner cavity.

[0192] The container's geometric parameters include the track's cross-sectional dimensions, which are extracted and determined.

[0193] S904: Calculate the number of balls to be launched simultaneously based on the track cross-section dimensions and attachment conditions.

[0194] The number of balls launched simultaneously refers to the number of gravity balls released simultaneously in a single launch.

[0195] First, calculate the maximum number of balls that can be accommodated in a single run based on the cross-sectional area of ​​the track. Then, match the minimum number of balls required for cleaning based on the severity of the adhesion. Take the reasonable intersection of the two (without exceeding the upper limit of space and meeting the cleaning requirements) to get the number of balls to be launched simultaneously. This is common knowledge in the field of art and will not be elaborated here.

[0196] S905: Control the gravity ball to release the number of balls launched synchronously to complete the clearing.

[0197] Control the gravity ball to launch and release the balls synchronously, thereby clearing the area through the impact of multiple balls.

[0198] Reference Figure 3 A gravity ball is placed on the track to assist the stirring of ink by the stirring rod inside the mixing container.

[0199] Based on the same inventive concept, embodiments of the present invention provide a control system for a gravure ink production line, comprising: The acquisition module is used to acquire ink parameters, container geometric parameters, liquid level height values, and device parameter water level height values. The memory is used to store the program that implements the control method of any gravure ink production line; The processor loads and executes programs from memory.

[0200] Those skilled in the art will clearly understand that this description is for convenience and brevity, using only the above-described functional module division as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0201] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A control method for a gravure ink production line, characterized in that, include: Collect the ink parameters, container geometry parameters, preset liquid level height value and device parameters of the ink to be processed; The feeding height value of the conveying device is determined based on the device parameters, and the pigment reference information is determined based on the ink parameters. When the liquid level is lower than the feeding height, the pigment liquid in the mixing container is transported to the conveying device, the feeding command is output simultaneously, and the water level in the mixing container is collected. The inlet angle and inlet height are determined based on the water level and container geometry. In response to the feeding command, the pigment liquid is injected into the mixing container at the inlet angle and inlet height, and a preset gravity ball is placed to assist in the mixing. After the mixing is completed, the gravity ball is retrieved to sample the pigment to obtain pigment information. Based on the pigment information and pigment reference information, the feeding information is determined and the pigment liquid in the mixing container is fed with the feeding information.

2. A control method for a gravure ink production line according to claim 1, characterized in that, The steps for determining the inlet angle and inlet height based on the water level and container geometry include: The viscosity of the pigment solution and the stirring time are determined based on the ink parameters; Determine the container diameter based on the container's geometric parameters; The stirring force should be matched according to the viscosity of the pigment solution; Calculate the radius of curvature of the liquid surface based on the water level and container diameter; The water inlet angle is matched according to the radius of curvature and the viscosity of the pigment liquid; The water inlet height is determined based on the stirring time and stirring intensity.

3. A control method for a gravure ink production line according to claim 1, characterized in that, After being poured into the mixing container, it also includes: When a vortex is formed inside the mixing container, the vortex kinetic energy received by the preset stirring rod is collected simultaneously. The starting energy is determined based on the pigment reference information, and the vortex kinetic energy is updated to determine the stirring power when it is less than the starting energy. In response to the feeding command, the stirring rod is controlled by the stirring power to stir. Stirring ends when the vortex kinetic energy is equal to the start-up energy or the vortex kinetic energy is zero.

4. A control method for a gravure ink production line according to claim 3, characterized in that, The steps for collecting the vortex kinetic energy of a pre-set stirring rod include: Real-time vortex velocity and shear stress at the vortex center were collected; When the shear stress is not zero, an unlock command is output; In response to the unlock command, the preset stirring rod is controlled to collect kinetic energy. The rotation radius and angular velocity of the vortex are determined based on the vortex velocity and the preset stirring radius. The energy loss value of the vortex is determined based on the shear stress and the rotational angular velocity of the vortex. The initial value of the vortex kinetic energy is calculated based on the vortex's rotation radius and energy loss value; The vortex kinetic energy is determined based on the initial value of the vortex kinetic energy and the stirring power.

5. A control method for a gravure ink production line according to claim 1, characterized in that, Methods for recovering gravity balls for pigment sampling include: Collect the liquid level fluctuation value of the pigment liquid, the position of the gravity ball, and the pressure parameters at the bottom of the container; The relative distance between the gravity sphere and the container outlet, and the recovery path, are determined based on the position of the gravity sphere and the container geometry. Match fluctuation thresholds based on water level and pressure parameters; Until the liquid level fluctuation value is less than the fluctuation threshold, the preset recovery device will recover the gravity ball along the recovery path and move it to the preset sampling area to sample the pigment on the surface. After sampling, return the sample to its pre-positioned location within the mixing container to complete the gravity ball recovery and pigment sampling.

6. A control method for a gravure ink production line according to claim 1, characterized in that, Also includes: Collect data on the adhesion to the inner wall of the mixing container and the liquid level fluctuation value; The attachment threshold is matched based on the container geometry parameters; The thickness of the adhesion layer and the vibration frequency are determined based on the adhesion conditions and container geometry. Based on the container geometry parameters, the region where the adhesion layer thickness is greater than the adhesion threshold is determined, and this region is defined as the excessively thick region. The required number of balls is determined based on the excessively thick region; The window time point for selecting the lowest point of liquid level is determined based on the water level height and liquid level fluctuation value. In response to the cleaning command, the preset cleaning device is controlled by the vibration frequency to vibrate the outer wall of the mixing container, and gravity balls are released according to the number of small balls and the window time point to clean the attached pigment.

7. A control method for a gravure ink production line according to claim 6, characterized in that, Methods for collecting data on adhesion include: Collect the sound waves from the trajectory of a falling gravity ball; Wave images are extracted from the orbital acoustic waves to identify wave points; Determine the fluctuation thickness based on the fluctuation point; The attachment location is determined based on the wave image and container geometry. The adhesion status is determined based on the adhesion location and fluctuating thickness.

8. A control method for a gravure ink production line according to claim 6, characterized in that, Cleaning the attached pigment also includes: The natural frequency of the gravity ball during rolling and the damping parameters of the preset cleaning device are collected. Determine the persistence threshold based on adhesion conditions and container geometry; Based on the container's geometric parameters and damping parameters, the region where the adhesion layer thickness is greater than the stubbornness threshold is determined and defined as the stubborn region; The frequency coefficient is determined based on the vibration frequency and the natural frequency; The resonance timing is determined based on the frequency coefficient and the stubborn region, and the window time point is updated with the resonance timing. In response to the cleaning command, the vibration frequency is adjusted in real time using a frequency coefficient to control the cleaning device to vibrate the outer wall of the mixing container, and gravity balls are released according to the number of small balls and the window time point to complete the cleaning.

9. A control method for a gravure ink production line according to claim 8, characterized in that, The steps for launching the gravity ball also include: The resistance value of the gravity sphere inside the track is determined based on the acoustic waves of the track. Match the safety threshold based on the number of balls; When the resistance value exceeds the safety threshold, the continuous launch of a single ball is suspended and the launch of multiple balls is switched to synchronous launch. Determine the track cross-sectional dimensions based on the container's geometric parameters; The number of balls to be launched simultaneously is calculated based on the track cross-section dimensions and adhesion conditions; Control the gravity ball to launch and release the balls synchronously to complete the clearing.

10. A control system for a gravure ink production line, characterized in that, include: The acquisition module is used to acquire ink parameters, container geometric parameters, liquid level height values, and device parameter water level height values. A memory for storing a program that implements the control method for any one of the gravure ink production lines according to claims 1 to 9; The processor loads and executes programs from memory.

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