A temperature intelligent regulation method for hydrogel production process

Abstract

This invention discloses a method for intelligent temperature control in the hydrogel production process, specifically relating to the field of intelligent temperature control. It addresses the problems of uneven temperature distribution during heating, leading to asynchronous gelation and poor product consistency. The method involves periodically collecting and calculating changes in contact thermal resistance of the heating power of each temperature control unit in the heating plate array to identify the completion status of each region. Based on the spatial distribution of the heating support plane, concentric rings are constructed, and the differences in completion time within different rings are quantified to obtain a synchronization deviation index. Furthermore, for regions with significant deviations, lagging and leading units are identified, and their temperatures are compensated and reduced based on radial temperature gradients and boundary adjacency characteristics, respectively. This ensures that the gelation process in each region becomes more consistent, thereby achieving adaptive control of the temperature field and improving the stability and uniformity of the overall preparation process.

Description

Technical Field

[0001] This invention relates to the field of intelligent temperature control technology, and more specifically, to an intelligent temperature control method for hydrogel production processes. Background Technology

[0002] In actual production scenarios, the supporting surface of the heating process is often irregularly shaped, and the contact state between it and the heating plate varies. Furthermore, the boundary areas are easily affected by environmental heat dissipation, resulting in a spatially uneven temperature field distribution. Under these conditions, there is a significant time difference in the gelation process in different regions, with some areas completing the process earlier or later, thus affecting the consistency and stability of the final product.

[0003] In existing technologies, such as those used for hydrogel preparation, temperature regulation is often achieved by setting a constant overall temperature or using simple zone-based temperature control. This lacks fine-grained responsiveness to spatial distribution differences and real-time state changes, making it difficult to effectively suppress asynchronous gelation caused by uneven temperature distribution. Furthermore, traditional solutions typically focus on adjusting material formulations or process parameters, paying insufficient attention to the control mechanism for dynamic temperature regulation during production.

[0004] Therefore, it is necessary to propose a targeted intelligent temperature control method for the production process. By monitoring and analyzing the status of each temperature control unit in the heating plate array in real time and combining the spatial position relationship, the temperature is adaptively adjusted. From the control perspective, the synchronous optimization of the state transformation process is achieved. By constructing a temperature collaborative adjustment mechanism, the overall temperature uniformity and process stability are improved. The technical solution is universal and can empower the production process of hydrogels or other temperature control fields without directly relying on the material formulation and process configuration parameters of hydrogels. Summary of the Invention

[0005] In order to overcome the above-mentioned defects of the prior art, embodiments of the present invention provide a method for intelligent temperature control in the hydrogel production process to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A method for intelligent temperature control in hydrogel production processes includes the following steps: S1. Record the two-dimensional projection coordinate sequence of the heating support plane above the heating plate array, wherein the heating plate array is composed of discretely arranged temperature control units; S2. Periodically collect the heating power signal required by each temperature control unit to maintain the current temperature, calculate the ratio of the current period heating power value to the initial period heating power value, and use it as the contact thermal resistance increment of the bottom surface of the corresponding heating bearing plane of the corresponding temperature control unit. S3. For each temperature control unit, when the incremental contact thermal resistance of the unit is detected to be greater than the preset thermal resistance change threshold within a set number of consecutive sampling cycles, the temperature control unit is marked as a unit that has completed the transition. S4. Along the geometric center of the projected contour of the heating bearing plane towards the boundary, divide the temperature control unit into several concentric rings according to the shortest geometric path distance. Calculate the range of the timestamps of the transformation completion time of each temperature control unit in the same ring as the synchronization deviation index of the ring. S5. For rings where the synchronization deviation index is greater than the set allowable upper limit, identify the lagging units in the rings whose completion time is later than the average completion time of the rings, calculate the hysteresis compensation amount based on the hysteresis duration and the reference slope of the ring radial temperature gradient, and perform compensation adjustment on the temperature of the lagging units. S6. Synchronously identify advanced units within the ring whose completion time is earlier than the average completion time of the ring, calculate the advanced reduction amount based on the advanced duration and boundary adjacency parameters, and perform reduction adjustment on the temperature of the advanced units. The boundary adjacency parameters are calculated based on the boundary length corresponding to the unit area within the neighborhood of the temperature control unit. S7. When the synchronization deviation index of all concentric rings is within the set upper limit of the ring, restore the initial temperature parameters of the temperature control unit of the heating plate array.

[0008] As a further aspect of the present invention, in step S1, recording the two-dimensional projection coordinate sequence of the heating support plane above the heating plate array specifically includes: Obtain the coordinates of the placement reference point and rotation angle of the heating support plane in the heating plate array plane. Based on the preset planar geometric dimension data of the heating support plane, map the area enclosed by the outer contour of the heating support plane onto the discrete grid plane composed of the center coordinates of each temperature control unit. Extract the center coordinates of the temperature control unit within the area enclosed by the outer contour line and arrange them in the adjacent order of the discrete grid. Record the resulting coordinate sequence as a two-dimensional projected coordinate sequence of the heating bearing plane.

[0009] As a further aspect of the present invention, in S2, the increase in contact thermal resistance of the bottom surface of the heating support plane corresponding to the temperature control unit specifically includes: In the first acquisition cycle after the gelation reaction starts, the actual heating power value of each temperature control unit under the condition of maintaining the preset temperature setting value in the first acquisition cycle is recorded and used as the initial cycle heating power value. Starting from the second acquisition cycle, the actual heating power value of each temperature control unit in the current cycle is read as the heating power value of the current cycle in each acquisition cycle. The ratio of the heating power value of the current cycle to the heating power value of the initial cycle is used as a parameter to characterize the change in contact thermal resistance. The contact thermal resistance increment corresponding to each temperature control unit is calculated according to the pre-calibrated power-thermal resistance mapping relationship.

[0010] As a further aspect of the present invention, in step S3, marking the temperature control unit as the conversion completion unit specifically includes: Each temperature control unit is assigned an engineering counter. At the end of each acquisition cycle, if the increase in contact thermal resistance of the temperature control unit is greater than the preset thermal resistance change threshold, the counter is incremented by one; otherwise, the counter is cleared. When the counter reaches the set cycle number threshold, the temperature control unit is marked as a transition completion unit, and the current time is recorded as its transition completion time.

[0011] As a further aspect of the present invention, in step S4, the synchronization deviation index of the ring band specifically includes: The geometric center coordinates of the region enclosed by the outer contour of the heating support plane are calculated based on the two-dimensional projection coordinate sequence of the heating support plane. The straight-line distance from the center coordinate to the geometric center coordinate of each temperature control unit is calculated, and the straight-line distance is divided into a set number of continuous intervals according to a preset radial step size. Temperature control units falling within the same range are formed into a concentric ring. For each ring, the recorded completion time of each temperature control unit within that ring is retrieved. The latest completion time and the earliest completion time are extracted, and the time difference between the latest completion time and the earliest completion time is calculated as the synchronization deviation index of that ring.

[0012] As a further aspect of the present invention, in step S5, the temperature compensation adjustment of the hysteresis unit specifically includes: For rings where the synchronization deviation index is greater than the set allowable upper limit, the timestamps of the transition completion times of all temperature control units within the ring are extracted and the arithmetic mean is calculated as the average completion time of the ring. Temperature control units whose completion time in the ring belt is later than the average completion time of the ring belt are identified as lagging units, and the difference between the completion time of the lagging unit and the average completion time of the ring belt is used as the lag time. Along the radial direction of the ring, from the inside out, find all normal temperature control units that are within the acceptable fluctuation range of the average completion time of the ring, and extract the temperature sequence and the corresponding radial distance value sequence of all normal temperature control units. Linear fitting is performed on the temperature sequence and the radial distance value sequence. The slope of the obtained fitted line is used as the reference slope of the radial temperature gradient of the ring. The hysteresis compensation amount is obtained by multiplying the hysteresis duration and the reference slope of the radial temperature gradient of the ring. The current temperature of the hysteresis unit is increased by the hysteresis compensation amount and then written into the temperature controller.

[0013] As a further aspect of the present invention, in S6, the temperature reduction adjustment of the advanced unit specifically includes: For ring belts where the synchronization deviation index is greater than the set allowable upper limit, the temperature control units whose completion time is earlier than the average completion time of the ring belt are judged as leading units, and the difference between the average completion time of the ring belt and the completion time of the leading units is used as the lead time. For each advanced element, a preset neighborhood window centered on the center coordinates of the advanced element is determined on the discrete grid plane. The number of grid points located on the projected contour boundary of the heating bearing plane within the window is counted as the boundary length characterization value. The ratio obtained by dividing the boundary length characterization value by the total number of grid points within the window is used as the boundary adjacency parameter of the advanced element. The product of the lead time and the boundary adjacency parameter is calculated as the lead reduction coefficient. The lead reduction amount is obtained by normalizing the difference range between the lead reduction coefficient and the temperature of the temperature control unit in the ring. The lead reduction amount is written into the temperature controller after subtracting the lead reduction amount from the current temperature of the corresponding lead unit.

[0014] The technical effects and advantages of the intelligent temperature control method for hydrogel production process of the present invention are as follows: This invention addresses the asynchronous gelation problem caused by uneven temperature distribution during hydrogel production. It provides an intelligent temperature control scheme based on the coordinated adjustment of multiple temperature control units. By real-time acquisition of the heating power of each temperature control unit and calculation of contact thermal resistance changes, it achieves dynamic perception of local states and uses this as a criterion for completion, accurately reflecting the transformation process in different regions. Furthermore, by constructing a concentric ring division mechanism, the spatial distribution problem is transformed into a regional synchronicity evaluation problem, and the synchronization deviation index is used to quantitatively characterize the completion differences in each region, achieving precise localization of the temperature unevenness problem. Based on this, a compensation adjustment mechanism based on radial temperature gradient is introduced for lagging regions, and a reduction adjustment mechanism based on boundary adjacency characteristics is introduced for leading regions. Differential control is implemented based on different physical influencing factors, making the gelation process in each region more consistent, thereby significantly improving the consistency and stability of the overall product. Simultaneously, this scheme does not rely on complex material models or additional sensing devices; it can achieve adaptive adjustment using existing temperature control units, offering advantages such as a clear implementation path, high control precision, and strong engineering application feasibility. Attached Figure Description

[0015] Figure 1This is a schematic diagram of a method for intelligent temperature control in the hydrogel production process according to the present invention. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0017] Example 1 Figure 1 This invention provides a method for intelligent temperature control in the hydrogel production process, comprising the following steps: S1. Record the two-dimensional projection coordinate sequence of the heating support plane above the heating plate array, wherein the heating plate array is composed of discretely arranged temperature control units; S2. Periodically collect the heating power signal required by each temperature control unit to maintain the current temperature, calculate the ratio of the current period heating power value to the initial period heating power value, and use it as the contact thermal resistance increment of the bottom surface of the corresponding heating bearing plane of the corresponding temperature control unit. S3. For each temperature control unit, when the incremental contact thermal resistance of the unit is detected to be greater than the preset thermal resistance change threshold within a set number of consecutive sampling cycles, the temperature control unit is marked as a unit that has completed the transition. S4. Along the geometric center of the projected contour of the heating bearing plane towards the boundary, divide the temperature control unit into several concentric rings according to the shortest geometric path distance. Calculate the range of the timestamps of the transformation completion time of each temperature control unit in the same ring as the synchronization deviation index of the ring. S5. For rings where the synchronization deviation index is greater than the set allowable upper limit, identify the lagging units in the rings whose completion time is later than the average completion time of the rings, calculate the hysteresis compensation amount based on the hysteresis duration and the reference slope of the ring radial temperature gradient, and perform compensation adjustment on the temperature of the lagging units. S6. Synchronously identify advanced units within the ring whose completion time is earlier than the average completion time of the ring, calculate the advanced reduction amount based on the advanced duration and boundary adjacency parameters, and perform reduction adjustment on the temperature of the advanced units. The boundary adjacency parameters are calculated based on the boundary length corresponding to the unit area within the neighborhood of the temperature control unit. S7. When the synchronization deviation index of all concentric rings is within the set upper limit of the ring, restore the initial temperature parameters of the temperature control unit of the heating plate array.

[0018] In step S1, the two-dimensional projection coordinate sequence of the heating support plane above the heating plate array is recorded.

[0019] The heating plate array consists of regularly arranged temperature control units. Each temperature control unit is the smallest temperature control execution area in the heating plate array with independent temperature detection and adjustment capabilities. After physical installation, each temperature control unit corresponds to a unique spatial coordinate, which is obtained through initial equipment calibration. The calibration method adopts standard mechanical positioning and measurement. During the installation and commissioning phase, a high-precision ruler or visual calibration device is used to measure the center position of the temperature control unit, and the measurement results are recorded in two-dimensional coordinate form, thus forming a discrete grid coordinate set for the entire heating plate array. When the heating support plane enters the heating plate array, it is positioned by a preset placement fixture with a fixed reference point. When the heating support plane is placed, a certain characteristic corner point of it is aligned with this reference point, thereby determining the placement reference point coordinates of the heating support plane within the heating plate array plane. The rotation angle is obtained by detecting the angle between the edge of the heating support plane and the coordinate axis of the heating plate array. Specifically, two points are selected on the edge of the heating support plane, and the tilt direction of the edge relative to the array coordinate axis is calculated to obtain the rotation angle. The rotation angle is expressed in angle form, with a value range of 0° to 360°. The rotation angle is 0° when the edge of the heating support plane is parallel to the array coordinate axis. After obtaining the coordinates of the placement reference point and the rotation angle, the preset planar geometric dimension data of the heating support plane is read. This data comes from the structural parameters in the process design stage, including length, width, and outer contour shape description information. If the heating support plane is a regular rectangle, the length and width parameters are directly used to construct the outer contour line. If it is an irregular shape, the boundary point set method is used to describe the outer contour. During the mapping process, the outer contour line is rigidly rotated according to the rotation angle, using the placement reference point as the starting reference point, so that its direction is consistent with the actual placement state. Then, the rotated outer contour line is translated as a whole to the position of the placement reference point, thereby obtaining the actual outer contour position of the heating support plane in the heating plate array plane. Subsequently, the outer contour line is superimposed on the discrete grid plane. The spatial mapping process is completed by determining whether the center coordinates of the temperature control unit are located within the area enclosed by the outer contour line. In actual implementation, a point-by-point judgment method is adopted to determine the region affiliation of the center coordinates of each temperature control unit. When the coordinates are located within the area enclosed by the outer contour line, it is marked as an effective coverage unit, thereby forming the spatial coverage range of the heating bearing plane on the heating plate array. This range is expressed in the form of a set of temperature control units.

[0020] After mapping the heating support plane region, all temperature control units marked as effective coverage units are first classified, distinguishing those near the outer contour boundary from those inside. Boundary determination uses an adjacency judgment method. For each effective coverage unit, it checks whether there are any unmarked temperature control units in its adjacent positions in the discrete mesh. If so, the temperature control unit is determined as a boundary unit; otherwise, it is determined as an internal unit. Subsequently, the set of boundary temperature control units is sequentially arranged. The arrangement method is based on mesh adjacency relationships. Specifically, any boundary temperature control unit is selected as the starting point, and it traverses along its adjacent boundary units in the discrete mesh one by one, visiting all boundary temperature control units in a clockwise or counterclockwise direction. The visiting order is recorded during the traversal until the starting point is returned, thus forming a closed boundary path sequence. This path sequence reflects the outer contour shape of the heating support plane in the discrete mesh and has continuity and uniqueness. In practical implementation, to ensure traversal stability, the boundary temperature control unit with the smallest coordinate value is preferentially selected as the starting point, and the traversal direction is fixed as clockwise. After obtaining the sequential arrangement of the boundary temperature control units, the arrangement result is recorded in the form of a two-dimensional coordinate sequence. Each coordinate point corresponds to the center position of a temperature control unit, and all coordinate points are arranged sequentially according to the access order, forming a two-dimensional projected coordinate sequence of the heating bearing plane. This coordinate sequence is used for subsequent spatial analysis and zoning processing, and its length is determined by the number of boundary temperature control units. During the recording process, a unified data structure is used to store the coordinate sequence. Each coordinate point contains horizontal and vertical position values, ensuring that subsequent steps can directly perform distance calculations and region division when calling this sequence, thereby ensuring the continuity and consistency of the entire control process.

[0021] In S2, the contact thermal resistance increment is the corresponding temperature control unit's corresponding heating support plane bottom surface.

[0022] After the heating support plane is laid and enters the heating plate array, the start time of the gelation reaction is determined through process flow control. This start time is determined by the temperature stabilizing within the set value range and maintaining a continuous stable state. Specifically, the temperature reaches the target value and the fluctuation does not exceed ±0.5℃ within three consecutive sampling cycles. In the first sampling cycle corresponding to this start time, all temperature control units are synchronously sampled to obtain the actual heating power output value of each unit while maintaining the current temperature set value. The heating power is obtained through the power detection module inside the temperature control unit. This module directly reads the voltage and current in the heating circuit and converts them into a stable power value output by the electrical measurement circuit. To avoid the impact of instantaneous fluctuations on data stability, the power value within a single sampling cycle is processed using a time window averaging method. Specifically, five power data points are continuously sampled within the sampling cycle, and the average value is taken as the power value for that cycle, thus ensuring that the data reflects a stable heating state. The power values ​​of all temperature control units within this cycle are recorded to form an initial cycle heating power set, which is used as a reference benchmark for subsequent cycles. The physical state corresponding to this initial cycle is that the heating support plane and the heating plate are in initial contact. At this time, the interface has not undergone significant structural changes, the contact interface is tight and the heat conduction path is stable. Therefore, this power value can truly reflect the heat conduction requirements under the initial contact conditions.

[0023] Starting from the second acquisition cycle, power is continuously acquired from each temperature control unit, using the same acquisition method as the initial cycle, employing multiple samplings within the cycle and averaging the results to ensure data stability and reliability. For each temperature control unit, the power value obtained in the current acquisition cycle is compared with the corresponding power value in the initial cycle, and the ratio between the two is calculated. This ratio reflects the change in the energy required to maintain the temperature under the same set temperature conditions. In actual physical processes, when the heated support surface undergoes a gelation transition (or, for other types of products, different key process state transitions), its internal structure gradually changes from a liquid state to a network structure. Accompanied by material shrinkage or changes in interface state, the tightness of contact between the heated surface and the heating plate changes, thus affecting the interface heat transfer efficiency. When the contact worsens, the efficiency of heat transfer from the heating plate to the heated support surface decreases, requiring higher input power to maintain the same temperature, thus increasing the power value; conversely, when the contact improves, the required power decreases. Therefore, the power ratio directly reflects the changing trend of contact thermal resistance. To convert this ratio into a contact thermal resistance increment with practical physical meaning, a correspondence between power and contact thermal resistance is established in advance during the equipment calibration phase. The calibration process uses standard samples. Under known contact conditions, a series of stable operating conditions are obtained by gradually changing the interfacial pressure or contact area. The heating power required to maintain the same temperature is recorded under each condition, and the corresponding contact thermal resistance value is obtained using thermal testing methods, thus forming a set of power-thermal resistance data pairs. By fitting this data pair, a monotonically changing mapping curve is formed. In this embodiment, a piecewise linear fitting method is used to construct this relationship for quick table lookup or interpolation calculations during actual operation. During operation, the current power ratio is input into this mapping relationship, and the corresponding change in contact thermal resistance is obtained by looking up a table. This change is then compared with the initial thermal resistance to obtain the contact thermal resistance increment of each temperature control unit. This increment reflects the degree of change of the current state relative to the initial contact state.

[0024] In step S3, the temperature control unit is marked as the conversion completion unit.

[0025] An independent counting unit is established for each temperature control unit, and this counting unit is bound to the corresponding temperature control unit during the device initialization phase to ensure that the state determination process of each temperature control unit is independent and does not interfere with each other. The counting unit is uniformly set to zero value at the initial moment, and is updated only according to the change of contact thermal resistance of the corresponding temperature control unit during subsequent operation. At the end of each acquisition cycle, the incremental value of contact thermal resistance of the temperature control unit in the current cycle is retrieved from the contact thermal resistance calculation module and compared with the pre-set thermal resistance change threshold. The thermal resistance change threshold is obtained through calibration test. In the calibration process, a standard hydrogel sample is selected, and the change curve of contact thermal resistance during its transition from liquid to gel state is recorded under controlled temperature conditions. The thermal resistance change amplitude with obvious jump is used as the threshold reference value. In practical applications, 0.9 to 1.1 times of this reference value is selected as the threshold range, and the midpoint is fixed as the specific threshold. For example, when the calibration result is 0.15, the threshold is set to 0.15. When the contact thermal resistance change occurs within a certain acquisition cycle... When the increase in thermal resistance consistently exceeds the threshold, it indicates that the corresponding region of the temperature control unit has entered a stable structural transformation stage. At this point, the counting unit is incremented by one. When the increase in contact thermal resistance within a certain period is detected to be lower than the threshold, the counting unit is immediately reset to zero to avoid misjudgment caused by instantaneous disturbances or local anomalies. The set period threshold is also determined experimentally. After continuously monitoring the transformation process of multiple samples, the number of typical periods with continuous thermal resistance abrupt changes is counted, and the minimum number of consecutive periods that stably occur is selected as the threshold. When the accumulated count of the counting unit reaches the set period threshold, the corresponding temperature control unit is immediately marked as a transformation completion unit. The transformation completion corresponds to the completion of the gelation transformation. At the same time, the current time is latched as the transformation completion time of the temperature control unit. This time is obtained through a unified clock source, and the time accuracy is set to the millisecond level to ensure the accuracy of time comparison between different temperature control units. Throughout the entire determination process, the combination of continuity constraints and threshold determination ensures that status marking is only performed when the change in thermal resistance shows a stable abrupt trend.

[0026] In S4, the synchronization deviation index is used as the ring band.

[0027] The set of coordinate points constituting the outer contour boundary of the heating support plane is read from a two-dimensional projected coordinate sequence. This coordinate sequence can completely characterize the spatial contour of the heating support plane on the heating plate array. Based on this coordinate sequence, the geometric center position of the region enclosed by the outer contour line is calculated using standard polygon geometry processing. Specifically, the region equilibration method is adopted, which treats the outer contour as a closed planar region, assumes a uniform mass distribution in this region, and obtains the overall center position by integrating and accumulating the boundary points piecewise. In actual implementation, to avoid complex integral calculations, a discrete approximation method is used to divide the region into multiple small units, and the center positions of each unit are averaged to obtain the geometric center coordinates. This method has been widely verified in actual engineering, and the calculation results are stable and reliable. After the geometric center is determined, the center coordinates of each temperature control unit in the heating plate array are read, and the straight-line distance from it to the geometric center is calculated. The distance is calculated using the standard Euclidean distance method, obtained through coordinate difference. After calculating the distances of all temperature control units, the resulting distance values ​​are partitioned based on a preset radial step size. This radial step size is determined through equipment calibration. During calibration, a suitable value is selected based on the size range of the heating support plane and the distribution density of the temperature control units. In this embodiment, 5 mm is selected as the radial step size. When the size of the heating support plane is large, it can be proportionally increased to 10 mm to ensure that each interval contains a reasonable number of temperature control units. Based on this radial step size, the range from the minimum to the maximum distance is divided into several continuous intervals, each with the same width and no overlap, thus forming multiple concentric radial regions. Subsequently, each temperature control unit is assigned to its corresponding interval according to its distance value, and temperature control units in the same interval are uniformly classified into a concentric ring. This method achieves radial stratification of the entire support area, transforming the originally complex two-dimensional distribution into an ordered partitioned structure.

[0028] After dividing the concentric rings, a time difference analysis was performed on each ring. Specifically, the transition completion time data of all temperature control units within the ring were retrieved from the status recording module. This data originated from the completion time records obtained based on the continuous determination of contact thermal resistance abrupt changes, possessing a unified time benchmark and millisecond-level precision to ensure comparability between different temperature control units. After acquiring all completion time data within the ring, it was sorted from earliest to latest to ensure the orderliness of the time series. After sorting, the earliest and latest completion times were directly extracted as the time boundary values ​​within the ring. Subsequently, the time difference between the two was calculated, expressed in milliseconds, to reflect the degree of time dispersion in the transition completion of different temperature control units within the ring. A larger time difference indicates significant asynchrony in the gelation process within that region, while a smaller difference indicates relatively consistent gelation processes among the temperature control units within that region. In practice, to avoid the influence of extreme outliers on the results, the median and interquartile range are recorded simultaneously during the sorting process. When the completion time of individual temperature control units deviates significantly from the overall distribution, the earliest and latest times are recalculated after removing outliers to ensure that the synchronization deviation index reflects the overall trend rather than individual anomalies. The anomaly judgment criterion is set as a deviation from the median exceeding 50% of the overall time span; data exceeding this range are not included in the extreme value calculation. Finally, the obtained time difference is used as the synchronization deviation index for that ring.

[0029] In step S5, the temperature of the hysteresis unit is adjusted to compensate for the temperature change.

[0030] When the synchronization deviation index of a concentric ring exceeds a set allowable upper limit, the completion time data of all temperature control units within that ring are centrally processed. First, the recorded completion timestamps of all temperature control units within the ring are read uniformly. These timestamps are generated using the same clock source, maintaining millisecond-level time accuracy to ensure direct comparison of time data between different temperature control units. Then, all timestamps within the ring are summed and divided by the number of temperature control units to obtain the average completion time of the ring. This average value serves as the representative time of the overall transition process of the ring. In this embodiment, to avoid outliers significantly shifting the average value, the time series is filtered before calculating the average. The filtering method involves removing individual data points whose deviation from the median time exceeds 40% of the overall time span. In practical applications, this proportion is stable and effectively eliminates interference from local abnormal measurements on the average value. After the average value is calculated, the completion time of each temperature control unit is compared with the average value. Any temperature control unit whose completion time is later than the average value is uniformly determined as a lagging unit, and its corresponding time difference is recorded. This time difference is the lag duration, which physically means the degree of delay of the region relative to the overall average transformation progress.

[0031] After identifying the lagging units, temperature control units within the same ring that were not judged as lagging or leading are screened. The screening criterion is that their completion time falls within a stable range near the average completion time of the ring. This stable range is determined through experimental calibration. During the calibration process, the completion time distribution of a large number of samples is statistically analyzed, and data intervals deviating from the average value by no more than 20% of the total time span are considered stable intervals. In this embodiment, this range corresponds to approximately ±2 seconds. Temperature control units within this range are judged as normal temperature control units. Subsequently, the current temperature setpoint and corresponding radial distance value are extracted from these normal temperature control units. The radial distance is derived from the aforementioned geometric center distance calculation result to ensure data consistency. The temperature setpoints are sorted in ascending order of radial distance, and a data sequence of temperature variation with radial direction is constructed. In actual physical processes, heat conduction inside the heating bearing plane exhibits a trend of gradual attenuation from the center to the boundary. In a stable state, this variation relationship shows an approximately linear distribution within a local range. Therefore, using a linear fitting method to process this data sequence has a clear physical basis. The specific fitting method involves selecting at least three normal temperature control units distributed at different radial positions, pairing their temperature values ​​with radial distances, and determining a straight line based on the minimum error principle to minimize the total deviation of each data point from this line. This yields a fitted straight line reflecting the radial temperature change trend. The slope of this line is defined as the baseline slope of the annular radial temperature gradient, with units representing the ratio of temperature change to distance change, characterizing the temperature change amplitude per unit radial distance within the annulus. In this embodiment, to improve fitting stability, at least five data points are required for fitting. If insufficient data points meet the condition, the stable interval is automatically expanded until the minimum number requirement is met. After obtaining the slope, it is multiplied by the lag time of the corresponding hysteresis unit to obtain the hysteresis compensation amount. This compensation amount directly reflects the required increase in temperature, physically meaning that the temperature is increased to compensate for the time lag in the gelation process of this region. Finally, this compensation amount is superimposed on the current temperature setpoint of the hysteresis unit, and the updated temperature value is written into the control parameters of the corresponding temperature control unit, thereby completing the precise compensation adjustment for the hysteresis region.

[0032] In step S6, the temperature of the advanced unit is reduced and adjusted.

[0033] When the synchronization deviation index of a certain concentric ring exceeds the set allowable upper limit, the completion time data of all temperature control units within that ring are centrally analyzed. First, the completion timestamps of each temperature control unit within the ring are retrieved, and the average completion time of the ring is calculated based on a unified clock reference. This average is obtained using an arithmetic mean, and outliers deviating from the overall time distribution by more than 40% are removed before calculation to avoid individual anomalies interfering with the overall judgment. Then, the completion time of each temperature control unit is compared one by one with this average. Temperature control units whose completion time is earlier than the average are identified as leading units, and the difference between their completion time and the average completion time is recorded as the leading time, expressed in milliseconds, reflecting the degree to which the gelation process in that region is ahead of the overall process. After identifying the advanced units, a local spatial adjacency feature is constructed for each advanced unit. Specifically, in the discrete grid plane, a neighborhood window is constructed using the center coordinates of the advanced unit as the reference point. This neighborhood window is determined using a fixed size method. In this embodiment, a square area extending two layers of temperature control units outward from the center point is selected as the neighborhood range, ensuring that the neighborhood contains a sufficient number of grid points for statistical analysis. Subsequently, all grid points within the neighborhood window are traversed to determine whether each grid point is located on the boundary of the heating bearing plane's projected outline. Boundary determination is achieved by checking whether the grid point is adjacent to an uncovered area. When a grid point has at least one adjacent position that does not belong to the bearing area, it is identified as a boundary point. The total number of all boundary points within the neighborhood window is counted as the boundary length representation value, and the total number of grid points within the window is recorded. Divide the boundary length value by the total number of grid points in the window to obtain the boundary adjacency parameter. The value of this parameter is between 0 and 1. The larger the value, the closer the temperature control unit is to the boundary area of ​​the heating bearing plane, and the more paths its heat dissipates outward, and the more obvious the heat dissipation effect.

[0034] After obtaining the lead time and corresponding boundary adjacency parameters, the two are multiplied to obtain the lead reduction coefficient. This coefficient is used to comprehensively characterize the combined impact of the time lead degree and spatial heat dissipation characteristics on temperature regulation. To convert this coefficient into a meaningful temperature reduction amount, it is normalized. The specific steps are as follows: First, the completion time data of all temperature control units within the ring are collected, the latest completion time and the earliest completion time are extracted, and the time difference between the two is calculated. This time difference is used as the normalization reference time scale. In this embodiment, this time difference is usually between 5 and 15 seconds, depending on the actual operating conditions. Then, each lead reduction coefficient is divided by the reference time scale to obtain the normalized reduction coefficient. This normalization result is a dimensionless proportional value, and its value reflects the relative position of the current lead degree in the overall time distribution. After completing the time normalization, the temperature range is extracted. Specifically, the current temperature setpoints of all temperature control units within the ring are collected, the maximum and minimum values ​​are obtained, and the difference between the two is calculated as the temperature difference range. The normalized reduction coefficient is multiplied by the temperature difference range to obtain the final advance reduction amount. This reduction amount directly represents the temperature range that needs to be subtracted from the current temperature setpoint, and its value is positively correlated with the degree of advance. Finally, this reduction amount is subtracted from the current temperature setpoint of the corresponding advance unit, and the updated temperature value is written into the control parameters of the temperature control unit to realize the temperature adjustment of the advance region.

[0035] In step S7, when the synchronization deviation index of all concentric rings is within the set upper limit of the rings, the initial temperature parameters of the temperature control unit of the heating plate array are restored.

[0036] The synchronization deviation index of each concentric ring is periodically detected, with the detection cycle consistent with the aforementioned acquisition cycle. A unified time reference is used for triggering. At the end of each acquisition cycle, the synchronization deviation index values ​​corresponding to all concentric rings are sequentially read and compared one by one with a pre-set allowable upper limit. The allowable upper limit is determined through process calibration. During the calibration process, multiple batches of hydrogel samples are selected, and their synchronization deviation index distribution is recorded under different temperature control strategies. The maximum allowable time difference under the requirement of ensuring product uniformity is used as a threshold reference; in this embodiment, this threshold is set to 3 seconds. When the synchronization deviation index of all concentric rings is less than or equal to this threshold, it is determined that the current temperature control state has met the overall consistency requirement, and at this time, a temperature recovery operation is triggered.

[0037] The temperature recovery process employs a gradual callback method. The current temperature setpoints of each temperature control unit are uniformly processed. First, the initial temperature parameters recorded by each temperature control unit during the initialization phase are read; this initial temperature is the standard curing temperature set by the process. Then, the current temperature is gradually adjusted to the initial temperature value in fixed steps. The step size is determined experimentally and, in this embodiment, is set to 1°C per acquisition cycle to ensure a smooth temperature change and avoid disturbances to the internal structure of the material due to rapid cooling or heating. During the adjustment process, the synchronous deviation index of each zone is continuously monitored to ensure that no new deviations increase during temperature recovery, until the temperature of all temperature control units returns to the initial temperature parameters and remains stable. This method achieves a smooth transition from the dynamic control stage to the stable curing stage, ensuring the continuity and stability of the overall process.

[0038] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, as a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., infrared, wireless, microwave, etc.) means. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that includes one or more sets of available media. The available medium can be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium. The semiconductor medium can be a solid-state drive.

[0039] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0040] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and modules described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0041] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of modules is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or modules may be electrical, mechanical, or other forms.

[0042] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical modules; they may be located in one place or distributed across multiple network modules. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0043] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0044] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0045] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0046] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for intelligent temperature control in the hydrogel production process, characterized in that, Includes the following steps: S1. Record the two-dimensional projection coordinate sequence of the heating support plane above the heating plate array, wherein the heating plate array is composed of discretely arranged temperature control units; S2. Periodically collect the heating power signal required by each temperature control unit to maintain the current temperature, calculate the ratio of the current period heating power value to the initial period heating power value, and use it as the contact thermal resistance increment of the bottom surface of the corresponding heating bearing plane of the corresponding temperature control unit. S3. For each temperature control unit, when the incremental contact thermal resistance of the unit is detected to be greater than the preset thermal resistance change threshold within a set number of consecutive sampling cycles, the temperature control unit is marked as a unit that has completed the transition. S4. Along the geometric center of the projected contour of the heating bearing plane towards the boundary, divide the temperature control unit into several concentric rings according to the shortest geometric path distance. Calculate the range of the timestamps of the transformation completion time of each temperature control unit in the same ring as the synchronization deviation index of the ring. S5. For rings where the synchronization deviation index is greater than the set allowable upper limit, identify the lagging units in the rings whose completion time is later than the average completion time of the rings, calculate the hysteresis compensation amount based on the hysteresis duration and the reference slope of the ring radial temperature gradient, and perform compensation adjustment on the temperature of the lagging units. S6. Synchronously identify advanced units within the ring whose completion time is earlier than the average completion time of the ring, calculate the advanced reduction amount based on the advanced duration and boundary adjacency parameters, and perform reduction adjustment on the temperature of the advanced units. The boundary adjacency parameters are calculated based on the boundary length corresponding to the unit area within the neighborhood of the temperature control unit. S7. When the synchronization deviation index of all concentric rings is within the set upper limit of the ring, restore the initial temperature parameters of the temperature control unit of the heating plate array.

2. The intelligent temperature control method for hydrogel production process according to claim 1, characterized in that, In step S1, recording the two-dimensional projection coordinate sequence of the heating support plane above the heating plate array specifically includes: Obtain the coordinates of the placement reference point and rotation angle of the heating support plane in the heating plate array plane. Based on the preset planar geometric dimension data of the heating support plane, map the area enclosed by the outer contour of the heating support plane onto the discrete grid plane composed of the center coordinates of each temperature control unit. Extract the center coordinates of the temperature control unit within the area enclosed by the outer contour line and arrange them in the adjacent order of the discrete grid. Record the resulting coordinate sequence as a two-dimensional projected coordinate sequence of the heating bearing plane.

3. The intelligent temperature control method for hydrogel production process according to claim 1, characterized in that, In S2, the increase in contact thermal resistance of the bottom surface of the corresponding heating support plane of the corresponding temperature control unit specifically includes: In the first acquisition cycle after the gelation reaction starts, the actual heating power value of each temperature control unit under the condition of maintaining the preset temperature setting value in the first acquisition cycle is recorded and used as the initial cycle heating power value. Starting from the second acquisition cycle, the actual heating power value of each temperature control unit in the current cycle is read as the heating power value of the current cycle in each acquisition cycle. The ratio of the heating power value of the current cycle to the heating power value of the initial cycle is used as a parameter to characterize the change in contact thermal resistance. The contact thermal resistance increment corresponding to each temperature control unit is calculated according to the pre-calibrated power-thermal resistance mapping relationship.

4. The intelligent temperature control method for hydrogel production process according to claim 1, characterized in that, In step S3, marking the temperature control unit as the conversion completion unit specifically includes: Each temperature control unit is assigned an engineering counter. At the end of each acquisition cycle, if the increase in contact thermal resistance of the temperature control unit is greater than the preset thermal resistance change threshold, the counter is incremented by one; otherwise, the counter is cleared. When the counter reaches the set cycle number threshold, the temperature control unit is marked as a transition completion unit, and the current time is recorded as its transition completion time.

5. The intelligent temperature control method for hydrogel production process according to claim 1, characterized in that, In S4, the synchronization deviation index of the ring band specifically includes: The geometric center coordinates of the region enclosed by the outer contour of the heating support plane are calculated based on the two-dimensional projection coordinate sequence of the heating support plane. The straight-line distance from the center coordinate to the geometric center coordinate of each temperature control unit is calculated, and the straight-line distance is divided into a set number of continuous intervals according to a preset radial step size. Temperature control units falling within the same range are formed into a concentric ring. For each ring, the recorded completion time of each temperature control unit within that ring is retrieved. The latest completion time and the earliest completion time are extracted, and the time difference between the latest completion time and the earliest completion time is calculated as the synchronization deviation index of that ring.

6. The intelligent temperature control method for hydrogel production process according to claim 1, characterized in that, In step S5, the temperature compensation adjustment of the hysteresis unit specifically includes: For rings where the synchronization deviation index is greater than the set allowable upper limit, the timestamps of the transition completion times of all temperature control units within the ring are extracted and the arithmetic mean is calculated as the average completion time of the ring. Temperature control units whose completion time in the ring belt is later than the average completion time of the ring belt are identified as lagging units, and the difference between the completion time of the lagging unit and the average completion time of the ring belt is used as the lag time. Along the radial direction of the ring, from the inside out, find all normal temperature control units that are within the acceptable fluctuation range of the average completion time of the ring, and extract the temperature sequence and the corresponding radial distance value sequence of all normal temperature control units. Linear fitting is performed on the temperature sequence and the radial distance value sequence. The slope of the obtained fitted line is used as the reference slope of the radial temperature gradient of the ring. The hysteresis compensation amount is obtained by multiplying the hysteresis duration and the reference slope of the radial temperature gradient of the ring. The current temperature of the hysteresis unit is increased by the hysteresis compensation amount and then written into the temperature controller.

7. The intelligent temperature control method for hydrogel production process according to claim 1, characterized in that, In step S6, the temperature reduction adjustment of the advanced unit specifically includes: For ring belts where the synchronization deviation index is greater than the set allowable upper limit, the temperature control units whose completion time is earlier than the average completion time of the ring belt are judged as leading units, and the difference between the average completion time of the ring belt and the completion time of the leading units is used as the lead time. For each advanced element, a preset neighborhood window centered on the center coordinates of the advanced element is determined on the discrete grid plane. The number of grid points located on the projected contour boundary of the heating bearing plane within the window is counted as the boundary length characterization value. The ratio obtained by dividing the boundary length characterization value by the total number of grid points within the window is used as the boundary adjacency parameter of the advanced element. The product of the lead time and the boundary adjacency parameter is calculated as the lead reduction coefficient. The lead reduction amount is obtained by normalizing the difference range between the lead reduction coefficient and the temperature of the temperature control unit in the ring. The lead reduction amount is written into the temperature controller after subtracting the lead reduction amount from the current temperature of the corresponding lead unit.

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