Automatic Liquid Silica Mixing Control System Based on Dynamic Parameter Configuration and Flow Compensation

Abstract

This invention discloses an automatic proportioning control system for liquid silica gel based on dynamic parameter configuration and flow compensation, relating to the field of silica gel production control technology. It includes: a data acquisition module for real-time acquisition of operating data from production equipment, dynamically determining the current operating condition type based on a comparison of the operating data with preset thresholds; a dynamic parameter configuration module for storing control parameter sets corresponding to different operating condition types; a logic control module, whose core integrates a flow difference compensation algorithm to drive the actuator's action; a fault diagnosis module for continuously monitoring the equipment's operating status and the execution feedback of control commands; and a human-machine interaction module providing a graphical user interface. The advantages of this invention are: by introducing a collaborative control mechanism of dynamic parameter configuration and real-time flow compensation, it ensures consistent high product quality, effectively reduces raw material waste, and significantly improves production efficiency and system reliability.

Description

Technical Field

[0001] This invention relates to the field of silicone production control technology, specifically to an automatic proportioning control system for liquid silicone based on dynamic parameter configuration and flow compensation. Background Technology

[0002] In the automated production of liquid silicone, precise proportional control of component materials is crucial for ensuring product quality. Traditional control methods primarily rely on pre-set fixed parameters to control servo motors and valves, with control systems often being open-loop or simple closed-loop structures. However, the physical properties of liquid silicone components vary, such as viscosity and temperature sensitivity, and pipeline pressure and material characteristics fluctuate dynamically during continuous production. This static control mode struggles to adapt to complex dynamic conditions, leading to deviations between actual output ratios and set values, thus affecting product consistency and yield.

[0003] Existing technologies typically address these issues by increasing sensor monitoring frequency or relying on operators to manually adjust parameters based on experience. While the former increases data acquisition, it lacks intelligent data processing and decision-making algorithms, hindering autonomous parameter optimization. The latter heavily relies on operator skill levels, resulting in delayed adjustments, a lack of standardized procedures, low production efficiency, inconsistent product quality, and high labor costs. Specifically, this manifests as asynchronous flow responses due to differences in viscosity between components A and B, and difficulty in accurately injecting colorants due to mismatched pressure with the main material, ultimately leading to uncontrolled proportions, raw material waste, and product scrap. Therefore, the industry urgently needs an intelligent proportional control system capable of real-time sensing of operating conditions and automatic adjustment of control strategies. Summary of the Invention

[0004] To solve the above-mentioned technical problems, an automatic proportioning control system for liquid silica gel based on dynamic parameter configuration and flow compensation is provided. This technical solution solves at least one of the technical problems mentioned in the background.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An automatic proportioning control system for liquid silica gel based on dynamic parameter configuration and flow compensation includes: The data acquisition module is used to collect the operating data of the production equipment in real time. The operating data includes the servo motor speed, the flow rate and pressure value of component A, component B and colorant in the pipeline. The data acquisition module has a built-in operating condition identification unit. Based on the comparison of the operating data with a preset threshold, it dynamically determines the current operating condition type. The operating condition type includes at least automatic operation condition, manual debugging condition and abnormal alarm condition. The dynamic parameter configuration module is communicatively connected to the data acquisition module and is used to store control parameter sets corresponding to different working conditions. When the working condition identification unit determines the working condition switch, the dynamic parameter configuration module automatically calls and loads the corresponding target parameter set to the logic control module. The control parameter set includes at least servo motor operating parameters, safety threshold parameters, and proportional setting parameters. The logic control module integrates a flow difference compensation algorithm at its core. The logic control module is connected to the dynamic parameter configuration module and the field PLC controller. The logic control module receives the target parameter set and, based on the real-time collected flow data, generates servo motor speed adjustment instructions and colorant valve opening and closing control instructions through the flow difference compensation algorithm to drive the actuator to achieve high-precision dynamic proportional control between components A and B and the colorant. The fault diagnosis module is interconnected with the data acquisition module and the logic control module. It is used to continuously monitor the equipment operating status and the execution feedback of control commands. When the actual parameter value exceeds the safety threshold parameter or a hardware communication interruption is detected, the fault diagnosis module immediately triggers a multi-level alarm mechanism and executes a predefined fault handling process. The human-computer interaction module establishes communication connections with all the above modules, provides a graphical user interface, and is used to visually display real-time data, equipment status, and fault information to users. It also receives control commands and parameter modification commands input by users, enabling monitoring and intervention of the entire system.

[0006] Preferably, the workflow of the data acquisition module specifically includes: The data sensing and reading steps involve continuously acquiring analog and digital signals at fixed intervals using a high-precision sensor group. The sensor group includes at least a pressure transmitter for detecting pipeline pressure, a high-frequency flow meter for detecting material flow, and a liquid level sensor for detecting liquid level. The data preprocessing and operating condition identification steps involve filtering, unit conversion, and validity verification of the collected raw signals to obtain reliable operating data. The processed data is then matched with various preset operating condition judgment rules to automatically identify the specific operating condition of the system at present. The data distribution and storage steps distribute the pre-processed operating data and the identified operating condition types to the dynamic parameter configuration module, logic control module, and fault diagnosis module in real time, serving as the basis for their decision-making and control. At the same time, key historical data is stored in non-volatile memory for trend analysis and tracing.

[0007] Preferably, the workflow of the dynamic parameter configuration module specifically includes: The adaptive adjustment mechanism allows the dynamic parameter configuration module to automatically fine-tune the speed loop and torque loop parameters of the servo motor based on the flow and pressure change trends fed back by the data acquisition module and the built-in self-tuning algorithm when the system is in automatic operation mode, so that the system output can quickly respond to changes in material characteristics. The manual intervention mechanism allows authorized users to manually set, fine-tune, or save specific control parameters as new parameter templates through the parameter configuration interface provided by the human-machine interaction module when the system is in manual debugging or maintenance mode, in order to meet the needs of process testing or special production. The parameter set management mechanism and dynamic parameter configuration module maintain a parameter database to store and manage multiple complete sets of control parameters. Each set of parameters is uniquely bound to a specific product formula or operating condition, and supports one-click calling and switching, thereby achieving production flexibility.

[0008] Preferably, the traffic difference compensation algorithm integrated in the logic control module is as follows: For the proportional compensation algorithm of main components A and B, the algorithm is executed in the program loop interrupt of PLC, with an interrupt period of no more than 50 milliseconds. The algorithm calculates the instantaneous difference between the set flow rate and the actual feedback flow rate of components A and B in real time, and based on this difference and the rate of change, dynamically calculates the compensation amount for the servo motor speed through the proportional-integral controller, and corrects the motor control command in real time. The dynamic flow control algorithm for colorants is executed in an independent interrupt program segment with an interrupt cycle of 200 milliseconds. The algorithm calculates the theoretical injection amount of colorant in real time based on the set colorant ratio and main material flow rate, and dynamically adjusts the valve opening frequency and duty cycle by monitoring the actual discharge amount of the colorant valve to ensure the long-term accuracy and repeatability of the colorant ratio. The safety interlock control logic, acting as a protective layer for the compensation algorithm, continuously monitors key parameters. Once it detects a difference in flow ratio or a pipeline pressure that continuously exceeds the maximum allowable range set in the safety threshold parameters, it immediately overrides the conventional control logic, issues an emergency stop command, shuts down all servo motors and valves, and reports a serious fault.

[0009] Preferably, the fault handling process of the fault diagnosis module specifically includes: Abnormal state monitoring and diagnosis steps: The fault diagnosis module continuously compares the logic control instructions with the feedback signals of the actuator, and monitors whether the key operating parameters exceed the limits. For the abnormalities found, a preliminary diagnosis is made to determine their severity level, and they are classified as early warning, minor faults and major faults. The tiered response and recording process involves the following steps: For early warning information, the system will only provide a notification in the human-machine interaction module and continue to run. For minor faults, an audible and visual alarm will be triggered and a corresponding automatic adjustment strategy will be executed to attempt to eliminate the fault. For major faults and hardware communication interruptions, an emergency shutdown procedure will be initiated immediately, the power source will be cut off, and a detailed fault log will be generated, recording the fault code, occurrence time, and relevant parameter snapshots. The maintenance support and data traceability steps, and the fault diagnosis module record all equipment maintenance operations, including maintenance time, operators and modified parameters. It provides complete production data recording functions, and the recorded content includes at least pressure, flow rate, ratio difference, output statistics and timestamps. It supports querying and analysis by time period or product batch, and provides a data foundation for preventive maintenance and quality traceability.

[0010] Preferably, the functions provided by the human-computer interaction module specifically include: The real-time data visualization function dynamically displays key system operating data in various forms, such as digital and analog dashboards and real-time trend curves, at a refresh rate of no less than 1Hz. Interactive operation and control functions provide virtual buttons, sliders, parameter input boxes and other controls, supporting users to perform operations such as mode switching, manual start and stop, parameter setting, alarm confirmation and device reset. All operations must be verified by authorization and recorded in the operation log. The alarm management and historical query functions immediately notify users when a fault occurs, using eye-catching color coding and pop-up windows, and provide handling suggestions. It also provides a historical data query engine, allowing users to search, filter, and export historical operating data, alarm records, and operation logs.

[0011] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention brings significant benefits by introducing a collaborative control mechanism of dynamic parameter configuration and real-time flow compensation: the system can intelligently adapt to complex working condition changes during the production of liquid silicone, automatically compensate for the proportioning deviation caused by differences in material properties and pressure fluctuations, thereby greatly improving the accuracy and stability of proportional control; this not only ensures consistent high quality of products, but also effectively reduces the waste of raw materials, and at the same time, the high degree of automation reduces the dependence on external manual intervention, significantly improving production efficiency and system reliability, and optimizing the overall production cost. Attached Figure Description

[0012] Figure 1 This is a diagram of the automatic proportioning control system for liquid silica gel based on dynamic parameter configuration and flow compensation proposed in this scheme. Figure 2 This is a schematic diagram of the system structure of a specific embodiment of the proposed solution. Detailed Implementation

[0013] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0014] Reference Figure 1 As shown, the automatic proportioning control system for liquid silica gel based on dynamic parameter configuration and flow compensation includes: The data acquisition module is used to collect real-time operating data of the production equipment. The operating data includes the servo motor speed, the flow rate and pressure value of component A, component B and colorant in the pipeline. The data acquisition module has a built-in operating condition identification unit. Based on the comparison of the operating data and the preset threshold, it dynamically determines the current operating condition type. The operating condition type includes at least automatic operation condition, manual debugging condition and abnormal alarm condition. The dynamic parameter configuration module communicates with the data acquisition module and is used to store control parameter sets corresponding to different working conditions. When the working condition identification unit determines the working condition switch, the dynamic parameter configuration module automatically calls and loads the corresponding target parameter set to the logic control module. The control parameter set includes at least servo motor operating parameters, safety threshold parameters, and proportional setting parameters. The logic control module integrates a flow difference compensation algorithm at its core. The logic control module is connected to the dynamic parameter configuration module and the field PLC controller. The logic control module receives the target parameter set and, based on the real-time collected flow data, generates servo motor speed adjustment instructions and colorant valve opening and closing control instructions through the flow difference compensation algorithm to drive the actuator to achieve high-precision dynamic proportional control between components A and B and colorant. The fault diagnosis module, interconnected with the data acquisition module and the logic control module, is used to continuously monitor the equipment's operating status and the execution feedback of control commands. When the actual parameter value exceeds the safety threshold parameter or a hardware communication interruption is detected, the fault diagnosis module immediately triggers a multi-level alarm mechanism and executes a predefined fault handling process. The human-computer interaction module establishes communication connections with all the above modules, provides a graphical user interface, and is used to visually display real-time data, equipment status, and fault information to users. It also receives control commands and parameter modification commands input by users, enabling monitoring and intervention of the entire system.

[0015] Specifically, the working steps of the above system are as follows: System initialization and status self-check steps: After the system starts, the data acquisition module first performs the initialization operation, reads the initial values ​​of each sensor and performs calibration. At the same time, the fault diagnosis module performs a self-check on the system hardware communication status and key parameters. If a communication interruption or abnormal initial value is found, a fault alarm is issued through the human-machine interaction module and the startup process is stopped. Operating mode judgment and parameter preloading steps: After successful initialization, the data acquisition module continuously collects external signals to determine whether the current operating mode is manual or automatic. When it is determined to be automatic mode, the dynamic parameter configuration module judges whether the system meets the automatic operation conditions based on the real-time data provided by the data acquisition module. If it does, the dynamic parameter configuration module automatically loads the preset control parameter set corresponding to the current production formula and switches the system status to standby ready state. This status is indicated by the green indicator light of the human-machine interaction module. Automatic operation and real-time flow compensation steps: In standby ready state, the system waits for an external start signal. Once the start signal is received, the logic control module immediately outputs initial control commands to drive the servo motor and valve to start based on the target parameter set provided by the dynamic parameter configuration module. Subsequently, the logic control module activates its internal high-frequency interrupt program. This interrupt program works with the data acquisition module to collect the flow difference between components A and B in real time at a fixed period, and executes the flow difference compensation algorithm to dynamically adjust the speed of the servo motor. At the same time, it performs independent closed-loop control on the opening and closing cycle of the colorant valve to ensure the dynamic accuracy of the three-component ratio. Full-process safety monitoring and fault handling steps: During automatic operation, the fault diagnosis module works in parallel, continuously comparing the instructions issued by the logic control module with the actual operating data fed back by the data acquisition module. When parameter over-limit, proportional imbalance or hardware abnormality is detected, the fault diagnosis module sends instructions to the logic control module according to the preset safety logic to trigger a graded response, including: performing parameter fine-tuning, issuing an early warning, or performing an emergency shutdown, and records the fault information and sends it to the human-machine interaction module for display. Operation termination and status management steps: When production ends or an external stop signal is received, the logic control module controls the actuator to stop in an orderly manner. The system is not completely shut down, but the logic control module clears the running status and hands it over to the data acquisition module for monitoring. The system as a whole returns to the standby ready state and updates the system status display through the human-machine interaction module, waiting for the next start command.

[0016] Specifically, the workflow of the data acquisition module includes: The data sensing and reading steps involve continuously acquiring analog and digital signals at fixed intervals using a high-precision sensor group. The sensor group includes at least a pressure transmitter for detecting pipeline pressure, a high-frequency flow meter for detecting material flow, and a liquid level sensor for detecting liquid level. The data preprocessing and operating condition identification steps involve filtering, unit conversion, and validity verification of the collected raw signals to obtain reliable operating data. The processed data is then matched with various preset operating condition judgment rules to automatically identify the specific operating condition of the system at present. The data distribution and storage steps distribute the pre-processed operating data and the identified operating condition types to the dynamic parameter configuration module, logic control module, and fault diagnosis module in real time, serving as the basis for their decision-making and control. At the same time, key historical data is stored in non-volatile memory for trend analysis and tracing.

[0017] A hierarchical, multi-task parallel data processing pipeline was constructed. It not only completed the basic conversion from physical signals to digital information, but more importantly, through embedded intelligent diagnostic and condition recognition algorithms, it "purified" and "interpreted" the raw data, transforming simple data points into system state information with clear engineering semantics. This design enables subsequent modules, such as the dynamic parameter configuration module, to make decisions based on accurate and reliable condition judgments, rather than directly responding to raw signals that may contain noise. This significantly improves the accuracy and real-time performance of the system's perception through high-frequency acquisition and real-time preprocessing, enabling rapid and precise control in highly dynamic environments. The automated condition recognition function gives the system preliminary "cognitive" capabilities, allowing it to proactively adapt to the needs of different production stages, providing crucial support for upgrading control strategies from passive response to proactive optimization. The standardized data distribution and storage mechanism not only ensures the high efficiency of collaborative work among functional modules but also accumulates valuable digital assets for end-to-end traceability, quality analysis, and predictive maintenance of the production process, laying a solid data foundation for robust control.

[0018] The workflow of the dynamic parameter configuration module specifically includes: The adaptive adjustment mechanism allows the dynamic parameter configuration module to automatically fine-tune the speed loop and torque loop parameters of the servo motor based on the flow and pressure change trends fed back by the data acquisition module and the built-in self-tuning algorithm when the system is in automatic operation mode, so that the system output can quickly respond to changes in material characteristics. The manual intervention mechanism allows authorized users to manually set, fine-tune, or save specific control parameters as new parameter templates through the parameter configuration interface provided by the human-machine interaction module when the system is in manual debugging or maintenance mode, in order to meet the needs of process testing or special production. The parameter set management mechanism and dynamic parameter configuration module maintain a parameter database to store and manage multiple complete sets of control parameters. Each set of parameters is uniquely bound to a specific product formula or operating condition, and supports one-click calling and switching, thereby achieving production flexibility.

[0019] The dynamic parameter configuration module is implemented in the programmable logic controller (PLC) using a structured text language. Internally, the module establishes a parameter database that stores multiple parameter sets in the form of data blocks. Each parameter set is indexed by a unique recipe number and contains specific parameter values ​​such as servo motor proportional gain, integral time, speed feedforward, and various pressure / flow alarm thresholds. When the data acquisition module detects a change in operating condition or receives a recipe selection command from the human-machine interface module, this module executes the parameter set invocation and loading process through a dedicated function block. This function block reads all parameters corresponding to the target recipe number from the data block and atomically writes them to the corresponding control variable address of the logic control module, ensuring rapid and consistent parameter switching.

[0020] For the adaptive adjustment mechanism, a parameter self-tuning algorithm is embedded within the module. This algorithm runs as a background task, continuously monitoring the mean and standard deviation of the flow deviations of components A and B provided by the data acquisition module. When the deviation continues to exceed the dead zone, the algorithm fine-tunes the speed loop proportional gain of the servo drive according to preset adjustment rules (e.g., using the gradient descent method), and simultaneously sends the adjusted new parameter values ​​to the logic control module for execution and to update the current parameter set in the database, thereby achieving online self-learning and optimization of parameters. The manual intervention mechanism is implemented through a dedicated password-protected interface on the human-machine interaction module. Authorized users can modify the currently active parameter set, and the modification results take effect immediately or can be saved as a new recipe template. All parameter change history, including automatic adjustment records and manual operation records, is timestamped and stored in non-volatile memory for easy tracking and auditing.

[0021] The flow difference compensation algorithm integrated in the logic control module is as follows: For the proportional compensation algorithm of main components A and B, the algorithm is executed in the program loop interrupt of PLC, with an interrupt period of no more than 50 milliseconds. The algorithm calculates the instantaneous difference between the set flow rate and the actual feedback flow rate of components A and B in real time, and based on this difference and the rate of change, dynamically calculates the compensation amount for the servo motor speed through the proportional-integral controller, and corrects the motor control command in real time. The dynamic flow control algorithm for colorants is executed in an independent interrupt program segment with an interrupt cycle of 200 milliseconds. The algorithm calculates the theoretical injection amount of colorant in real time based on the set colorant ratio and main material flow rate, and dynamically adjusts the valve opening frequency and duty cycle by monitoring the actual discharge amount of the colorant valve to ensure the long-term accuracy and repeatability of the colorant ratio. The safety interlock control logic, acting as a protective layer for the compensation algorithm, continuously monitors key parameters. Once it detects a difference in flow ratio or a pipeline pressure that continuously exceeds the maximum allowable range set in the safety threshold parameters, it immediately overrides the conventional control logic, issues an emergency stop command, shuts down all servo motors and valves, and reports a serious fault.

[0022] In the PLC programming environment, the flow difference compensation algorithm is mainly implemented through the collaborative work of organization blocks (OB), function blocks (FB), and data structures (DB). The proportional compensation algorithm for main components A and B is written in a cyclic interrupt organization block with a period of 50 milliseconds. In this interrupt, the program first reads the actual flow values ​​of components A and B from the data block, which are collected by the high-frequency flow meter and processed by the data acquisition module. Then, it calculates the instantaneous deviation and rate of change of these values ​​from the set values. This deviation and rate of change are sent to a dedicated proportional-integral (PI) controller function block. This function block calculates and outputs a speed compensation amount in real time based on the proportional gain (Kp) and integral time (Ti) parameters provided by the dynamic parameter configuration module. This compensation amount is superimposed on the servo motor's reference speed command and sent to the servo driver in real time via the bus, thereby achieving closed-loop fine-tuning of the motor speed and dynamically offsetting the proportional deviation caused by viscosity and pressure fluctuations.

[0023] Dynamic flow control of the colorant is executed in a separate interrupt block with a period of 200 milliseconds. The algorithm kernel is a weight-time based controller. It first calculates the theoretical single injection weight of the colorant based on the total flow rate of the main material and the set color ratio. Then, the algorithm obtains the actual ejection weight of the current injection cycle by querying the reading of the high-precision scale installed on the colorant feeding device. By comparing the actual weight with the theoretical weight, the algorithm dynamically adjusts the opening time (duty cycle) and triggering frequency of the high-speed switching solenoid valve controlling the colorant valve in the next cycle, forming an independent closed-loop control to ensure the long-term accuracy and repeatability of the colorant ratio.

[0024] The safety interlock control logic runs with higher priority throughout all program segments. It continuously monitors the real-time proportional difference value calculated by the aforementioned algorithm and the feedback value from the pipeline pressure sensor. These values ​​are compared in real time with the preset absolute safety thresholds in the dynamic parameter configuration module. Once any parameter continuously exceeds the limit (e.g., exceeding the limit for three consecutive scan cycles), this logic will immediately set an emergency stop flag. This flag will override all regular control logic and directly call an emergency stop function block. This function block will send an "enable shut-off" command to all servo drives and valve output units, trigger audible and visual alarms, and simultaneously report fault codes and status snapshots through the human-machine interface module.

[0025] The fault handling process of the fault diagnosis module specifically includes: Abnormal state monitoring and diagnosis steps: The fault diagnosis module continuously compares the logic control instructions with the feedback signals of the actuator, and monitors whether the key operating parameters exceed the limits. For the abnormalities found, a preliminary diagnosis is made to determine their severity level, and they are classified as early warning, minor faults and major faults. The tiered response and recording process involves the following steps: For early warning information, the system will only provide a notification in the human-machine interaction module and continue to run. For minor faults, an audible and visual alarm will be triggered and a corresponding automatic adjustment strategy will be executed to attempt to eliminate the fault. For major faults and hardware communication interruptions, an emergency shutdown procedure will be initiated immediately, the power source will be cut off, and a detailed fault log will be generated, recording the fault code, occurrence time, and relevant parameter snapshots. The maintenance support and data traceability steps, and the fault diagnosis module record all equipment maintenance operations, including maintenance time, operators and modified parameters. It provides complete production data recording functions, and the recorded content includes at least pressure, flow rate, ratio difference, output statistics and timestamps. It supports querying and analysis by time period or product batch, and provides a data foundation for preventive maintenance and quality traceability.

[0026] The fault diagnosis module in the PLC achieves real-time monitoring through a high-priority cyclic interrupt organization block. Its core is a function block based on a state machine model. During the abnormal state monitoring and diagnosis process, this function block compares the command values ​​output by the logic control module (such as the servo motor's set speed) with the actual feedback values ​​read from the fieldbus in each scan cycle. Simultaneously, it continuously scans whether key operating parameters (such as pressure and flow) exceed the thresholds set in the dynamic parameter configuration module. The diagnostic logic employs multi-condition judgment: for example, if a single parameter momentarily exceeds the limit but quickly recovers, it is judged as a "warning"; if a parameter continuously exceeds the limit and the deviation is within a certain range, it is judged as a "minor fault"; if a parameter severely exceeds the limit, the deviation is too large, or a communication word, such as the "heartbeat signal" being lost, is detected, it is immediately judged as a "major fault."

[0027] In the graded response and recording process, the system triggers corresponding actions based on the diagnostic results. For "early warnings," the status indicator is updated only in the HMI-dedicated area, without affecting production. For "minor faults," the function block sets an internal flag, which triggers a preset automatic adjustment strategy in the logic control module (such as fine-tuning PID parameters) and simultaneously drives an audible and visual alarm to emit a flashing yellow warning. For "major faults," the function block immediately calls an emergency stop subroutine, which executes with the highest priority, sending a "rapid stop" command to all servo drives and closing all valves, while generating a detailed fault log. This log is recorded in a proprietary "alarm log DB," and includes at least: a precise timestamp generated by the system clock, the fault code, a snapshot of the relevant operating parameters at the time of the fault, and the currently active recipe number.

[0028] During the maintenance support and data traceability process, all parameter modifications made by operators after logging into the HMI are recorded in the "Operation Log DB". Simultaneously, the system cyclically stores key production data in a large "Production History DB" array at a configurable cycle. All these data blocks utilize non-volatile storage. Through the HMI's traceability interface, authorized personnel can query by time range, fault code, or product batch number. The system retrieves data from the corresponding DB and plots trend curves, providing comprehensive data support for analyzing root causes of failures, optimizing process parameters, and implementing predictive maintenance.

[0029] The specific functions provided by the human-computer interaction module include: The real-time data visualization function dynamically displays key system operating data in various forms, such as digital and analog dashboards and real-time trend curves, at a refresh rate of no less than 1Hz. Interactive operation and control functions provide virtual buttons, sliders, parameter input boxes and other controls, supporting users to perform operations such as mode switching, manual start and stop, parameter setting, alarm confirmation and device reset. All operations must be verified by authorization and recorded in the operation log. The alarm management and historical query functions immediately notify users when a fault occurs, using eye-catching color coding and pop-up windows, and provide handling suggestions. It also provides a historical data query engine, allowing users to search, filter, and export historical operating data, alarm records, and operation logs.

[0030] The core design of the human-machine interface module lies in constructing a centralized intelligent hub that is transparent, easy to operate, and well-managed. This module is not simply a data display and command receiving terminal; rather, it deeply integrates and visually reconstructs the real-time status of the data acquisition module, the operational logic of the logic control module, the alarm information of the fault diagnosis module, and the parameter set of the dynamic parameter configuration module. This provides users with a deep understanding and precise control over the entire production process. Its interactive operation and strict permission logging mechanism ensure the security and traceability of system operation, transforming complex automated control processes into an intuitive and reliable interactive experience. This significantly lowers the technical threshold for operators and is a key carrier for achieving intelligent and user-friendly system operation.

[0031] Specific references Figure 2 As shown, in a specific embodiment of this solution, the system hardware configuration is as follows: Controller: Siemens CPU1214 central processing module, 100 KB working memory; 24VDC power supply, onboard DI14 x 24VDC sink / source, DQ10 x 24VDC and AI2; onboard 6 high-speed counters and 4 pulse outputs; signal board expansion onboard I / O; up to 3 communication modules for serial communication; up to 8 signal modules for I / O expansion; 0.04ms / 1000 instructions; PROFINET interface for programming, HMI and PLC data communication.

[0032] Sensor: Pressure transmitter, current 4~20mA, pressure 0~400bar. Sensor: Liquid level sensor, voltage 0~10V, measuring range 0~1100mm. Flow meter, (1) VSE German brand, RS40 / 128, 413000 pulses / liter, maximum frequency 4.13KHZ, accuracy 0.5%; (2) VSE German brand, VSI02 / 128, 640000 pulses / liter, accuracy 0.5%.

[0033] Gear pump, ZPDA 2-6CC gear pump, including feeding screw, repeatability 0.1%.

[0034] Actuator: Servo drive, Siemens V90PN 6SL3210-5FE11-5UF0, drive voltage 400V, rated current 5.3A, rated power 1.5KW.

[0035] Servo motor, Siemens 1FL6064-1AC6x-xLB\Hx, rated power 1.5KW, rated current 4.6A, rated speed 2000 rpm, rated torque 7.16NM, encoder absolute value 20-bit + 12-bit multi-turn.

[0036] In summary, the advantages of this invention are as follows: By introducing a collaborative control mechanism of dynamic parameter configuration and real-time flow compensation, significant beneficial effects are achieved: the system can intelligently adapt to complex working condition changes during the liquid silicone production process, automatically compensate for ratio deviations caused by differences in material properties and pressure fluctuations, thereby greatly improving the accuracy and stability of ratio control; this not only ensures consistent high quality of products, but also effectively reduces waste of raw materials. At the same time, the high degree of automation reduces reliance on external manual intervention, significantly improving production efficiency and system reliability, and optimizing overall production costs.

[0037] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. A liquid silicone automatic proportioning control system based on dynamic parameter configuration and flow compensation, characterized in that, The application relates to a dynamic proportional control system for a colorant proportioning device, which comprises the following parts: a data acquisition module for acquiring running data of a production device in real time, wherein the running data comprises the rotating speed of a servo motor, the flow and pressure values of A-group components, B-group components and colorant in a pipeline, the data acquisition module is internally provided with a working condition recognition unit, the current working condition type is dynamically judged based on comparison between the running data and preset threshold values, and the working condition type at least comprises an automatic running working condition, a manual debugging working condition and an abnormal alarm working condition; a dynamic parameter configuration module in communication connection with the data acquisition module, used for storing control parameter sets corresponding to different working condition types, automatically calling and loading a corresponding target parameter set to a logic control module when the working condition recognition unit judges working condition switching, and the control parameter set at least comprises servo motor running parameters, safety threshold parameters and proportional setting parameters; a logic control module, the core of which is integrated with a flow difference compensation algorithm, the logic control module is connected with the dynamic parameter configuration module and a field PLC controller, the logic control module receives the target parameter set and generates servo motor rotating speed adjustment instructions and colorant valve opening and closing control instructions through the flow difference compensation algorithm based on real-time acquisition of flow data, so as to drive an actuating mechanism to act and realize high-precision dynamic proportional control between A-group components, B-group components and colorant; a fault diagnosis module interconnecting with the data acquisition module and the logic control module, used for continuously monitoring equipment running states and control instruction execution feedback, triggering a multi-stage alarm mechanism and executing a predefined fault handling process when actual parameter values exceed the safety threshold parameters or hardware communication interruption is detected; a man-machine interaction module in communication connection with all the modules, providing a graphical operation interface, used for visually showing real-time data, equipment states and fault information to a user, receiving control instructions and parameter modification instructions input by the user, and realizing monitoring and intervention on the whole system.

2. The automatic proportioning control system for liquid silicone based on dynamic parameter configuration and flow compensation according to claim 1, characterized in that, The working process of the data acquisition module specifically comprises the following steps: a data sensing and reading step, in which high-precision sensor groups are used to uninterruptedly acquire analog and digital signals at a fixed period, the sensor groups at least comprise a pressure transmitter for detecting pipeline pressure, a high-frequency flowmeter for detecting material flow and a liquid level sensor for detecting liquid level; a data preprocessing and working condition recognition step, in which original signals are filtered, unit-converted and validity-verified to obtain reliable running data, the processed data are matched with preset working condition judging rules to automatically recognize the specific working condition in which the system is currently located; a data distribution and storage step, in which the preprocessed running data and the recognized working condition type are distributed to the dynamic parameter configuration module, the logic control module and the fault diagnosis module in real time as the basis for decision and control, and key historical data are stored in a non-volatile memory for trend analysis and tracing.

3. The automatic proportioning control system of liquid silicone based on dynamic parameter configuration and flow compensation according to claim 2, characterized in that, The working process of the dynamic parameter configuration module specifically comprises the following steps: An adaptive adjustment mechanism, when the system is in automatic operation condition, the dynamic parameter configuration module automatically fine-tunes the speed loop and torque loop parameters of the servo motor based on the self-tuning algorithm embedded therein according to the flow and pressure change trend fed back by the data acquisition module, so that the system output quickly responds to the change of material characteristics; A manual intervention mechanism, when the system is in manual debugging condition or maintenance state, an authorized user can manually set, fine-tune or save specific control parameters as a new parameter template through the parameter configuration interface provided by the human-machine interaction module, so as to meet the needs of process test or special production; A parameter set management mechanism, the dynamic parameter configuration module maintains a parameter database to store and manage multiple complete sets of control parameters, each set of parameters is uniquely bound to a specific product formula or working condition, and one-key calling and switching are supported, so as to realize the flexibility of production.

4. The automatic proportioning control system of liquid silicone based on dynamic parameter configuration and flow compensation according to claim 3, characterized in that, The flow difference compensation algorithm integrated in the logic control module is specifically: A proportional compensation algorithm for A and B main components, the algorithm is executed in the program interruption of PLC, the interruption period is not greater than 50 milliseconds, the algorithm calculates the instantaneous difference value of the set flow and the actual feedback flow of A and B two components in real time, and according to the difference value and the change rate, the compensation amount of the servo motor speed is dynamically calculated through the proportional-integral controller to correct the motor control instruction in real time; A dynamic flow control algorithm for color agent, the dynamic flow control algorithm is executed in an independent interruption program segment, the interruption period is 200 milliseconds, the algorithm calculates the single theoretical injection amount of color agent in real time according to the set color agent proportion and main material flow, and dynamically adjusts the opening frequency and duty cycle of the valve to ensure the long-term accuracy and repeatability of the color agent proportion by monitoring the actual discharge amount of the color agent valve; Safety interlocking control logic, as a protection layer of the compensation algorithm, continuously monitors key parameters, and once detects that the flow proportion difference or the pipeline pressure continuously exceeds the maximum allowable range set in the safety threshold parameter, immediately overrides the conventional control logic, issues an emergency shutdown instruction, and shuts down all servo motors and valves, and reports a serious fault.

5. The automatic proportioning control system of liquid silicone based on dynamic parameter configuration and flow compensation according to claim 4, characterized in that, The fault handling process of the fault diagnosis module specifically includes: Abnormal state monitoring and diagnosis step, the fault diagnosis module continuously compares the logic control instruction and the feedback signal of the actuator, and monitors whether the key operating parameters are out of limits, and for the found abnormalities, performs preliminary diagnosis to determine the severity level, and distinguishes between warning, light fault and heavy fault; Graded response and recording step, for the warning information, only the human-machine interaction module is prompted, and the system continues to run, for the light fault, the sound and light alarm is triggered and the corresponding automatic adjustment strategy is executed to try to eliminate the fault, for the heavy fault and hardware communication interruption, the emergency shutdown process is immediately started, the power source is cut off, and detailed fault log is generated, recording fault code, occurrence time and related parameter snapshot; The maintenance support and data traceability steps, and the fault diagnosis module record all equipment maintenance operations, including maintenance time, operators and modified parameters. It provides complete production data recording functions, and the recorded content includes at least pressure, flow rate, ratio difference, output statistics and timestamps. It supports querying and analysis by time period or product batch, and provides a data foundation for preventive maintenance and quality traceability.

6. The automatic proportioning control system of liquid silicone based on dynamic parameter configuration and flow compensation according to claim 5, characterized in that, The specific functions provided by the human-computer interaction module include: The real-time data visualization function dynamically displays key system operating data in various forms, such as digital and analog dashboards and real-time trend curves, at a refresh rate of no less than 1Hz. Interactive operation and control functions provide virtual buttons, sliders, parameter input boxes and other controls, supporting users to perform operations such as mode switching, manual start and stop, parameter setting, alarm confirmation and device reset. All operations must be verified by authorization and recorded in the operation log. The alarm management and historical query functions immediately notify users when a fault occurs, using eye-catching color coding and pop-up windows, and provide handling suggestions. It also provides a historical data query engine, allowing users to search, filter, and export historical operating data, alarm records, and operation logs.

7. The automatic proportioning control system of liquid silicone based on dynamic parameter configuration and flow compensation according to claim 6, characterized in that, The system operates as follows: System initialization and status self-check steps: After the system starts, the data acquisition module first performs the initialization operation, reads the initial values ​​of each sensor and performs calibration. At the same time, the fault diagnosis module performs a self-check on the system hardware communication status and key parameters. If a communication interruption or abnormal initial value is found, a fault alarm is issued through the human-machine interaction module and the startup process is stopped. Operating mode judgment and parameter preloading steps: After successful initialization, the data acquisition module continuously collects external signals to determine whether the current operating mode is manual or automatic. When it is determined to be automatic mode, the dynamic parameter configuration module judges whether the system meets the automatic operation conditions based on the real-time data provided by the data acquisition module. If it does, the dynamic parameter configuration module automatically loads the preset control parameter set corresponding to the current production formula and switches the system status to standby ready state. This status is indicated by the green indicator light of the human-machine interaction module. Automatic operation and real-time flow compensation steps: In standby ready state, the system waits for an external start signal. Once the start signal is received, the logic control module immediately outputs an initial control command to drive the servo motor and valve to start based on the target parameter set provided by the dynamic parameter configuration module. Subsequently, the logic control module activates its internal high-frequency interrupt program. This interrupt program works with the data acquisition module to collect the flow difference between components A and B in real time at a fixed period, and executes the flow difference compensation algorithm to dynamically adjust the speed of the servo motor. At the same time, it performs independent closed-loop control on the opening and closing cycle of the colorant valve to ensure the dynamic accuracy of the three-component ratio. Full-process safety monitoring and fault handling steps: During automatic operation, the fault diagnosis module works in parallel, continuously comparing the instructions issued by the logic control module with the actual operating data fed back by the data acquisition module. When parameter over-limit, proportional imbalance or hardware abnormality is detected, the fault diagnosis module sends instructions to the logic control module according to the preset safety logic to trigger a graded response, including: performing parameter fine-tuning, issuing an early warning, or performing an emergency shutdown, and recording the fault information and sending it to the human-machine interaction module for display. Operation termination and status management steps: When production ends or an external stop signal is received, the logic control module controls the actuator to stop in an orderly manner. The system is not completely shut down, but the logic control module clears the running status and hands it over to the data acquisition module for monitoring. The system as a whole returns to the standby ready state and updates the system status display through the human-machine interaction module, waiting for the next start command.

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