Calender production line regulation system and method with crimping temperature feedback, and electronic device

Abstract

The application provides a calender production line regulation system and method of curling temperature feedback, and an electronic device, comprising: a temperature detection module arranged before a winding station of the calender production line, used for continuously detecting the curling temperature before the film is wound, and generating a temperature signal; a control module used for receiving the temperature signal, comparing the temperature signal with a preset temperature threshold, and outputting a regulation instruction according to the comparison result; a first execution mechanism used for executing a first regulation instruction output by the control module when the curling temperature is higher than a first temperature threshold, and executing an action of reducing the rotating speed of an extrusion unit of the production line; and a second execution mechanism used for executing a second regulation instruction output by the control module when the curling temperature is lower than a second temperature threshold, and executing an action of reducing or cutting off the supply of a cooling medium of a cooling unit, wherein the first temperature threshold is greater than the second temperature threshold. The application realizes accurate and cooperative regulation of the curling temperature of the calender production line, and improves the reliability and usability of the application.

Description

Technical Field

[0001] This invention relates to the field of collaborative control technology for calendering production lines, specifically to a calendering production line control system and method with coiling temperature feedback, and electronic equipment. Background Technology

[0002] Calendering is an important process in polymer material processing, widely used in the production of films, sheets, and various coated products. In a calendering production line, the film sheet exiting the calender rollers is cooled, drawn, and finally wound into a roll by a winding device. The temperature of the film sheet during winding, i.e., the winding temperature, is one of the core process parameters that determines the quality of the finished product. Too high a temperature will lead to increased shrinkage, adhesion, or deformation of the film sheet, while too low a temperature may cause the film sheet to harden and generate internal stress, affecting the flatness and dimensional stability of subsequent processing.

[0003] Currently, in most calendering production lines, temperature control still relies heavily on manual experience. Firstly, in temperature monitoring, intermittent sampling with handheld infrared thermometers is commonly used. Operators measure the temperature of the film surface before winding at regular intervals or when changing rolls. This monitoring method yields sparse data points, failing to reflect continuous dynamic temperature changes during production. By the time manual inspections detect excessive temperatures, defective film has often already been wound onto the roll, resulting in raw material waste and potential quality issues. Secondly, in temperature control, the lack of real-time temperature feedback forces operators to rely on personal experience. When the film temperature is too high, operators often reduce the machine speed or even shut it down immediately to suppress the temperature rise. This not only leads to production line instability but also impacts the uniformity of calendered product thickness due to sudden speed changes, creating new quality problems. Furthermore, for excessively low temperatures, existing production lines lack effective automatic heating or insulation methods, forcing operators to passively wait for the production line to naturally warm up, reducing production efficiency and equipment utilization. Furthermore, regarding cooling control, the cooling water system used for cooling drums on the production line employs rudimentary control methods. Its valves are mostly manual ball valves or shut-off valves, either remaining open during production or requiring manual operation. This results in significant waste of water and electricity, and prevents precise adjustments based on the real-time temperature requirements of the film. Finally, in terms of data management and traceability, key process parameters such as winding temperature, extruder speed, and cooling status are typically recorded on scattered paper forms or local equipment. These records are disconnected from production orders, rubber compound formulations, batch information, and other data, creating information silos. If downstream processes or customers report issues such as film shrinkage, deformation, or adhesion, technicians cannot quickly and accurately trace back to the precise process conditions and parameter curves during the production of that roll of film. This makes it difficult to analyze the cause of the problem, hinders data-driven process improvements, and restricts continuous improvement in production quality.

[0004] In summary, the existing methods for controlling the coiling temperature in calendering production lines are significantly inadequate in terms of real-time monitoring, precise control, efficient energy utilization, and data traceability, and cannot meet the current urgent needs of the manufacturing industry for high-quality, high-efficiency, low-energy-consumption, and intelligent production.

[0005] Therefore, the existing technology still needs further development. Summary of the Invention

[0006] The purpose of this invention is to overcome the above-mentioned technical deficiencies and provide a rolling production line control system and method with coiling temperature feedback, as well as electronic equipment, to solve the problems existing in the prior art.

[0007] To achieve the above-mentioned technical objectives, according to a first aspect of the present invention, the present invention provides a calendering production line control system with coiling temperature feedback, comprising: The temperature detection module is installed in front of the winding station of the calendering production line to continuously detect the winding temperature of the film before winding in real time and generate a temperature signal. The control module, connected to the temperature detection module, is used to receive the temperature signal, compare the temperature signal with a preset temperature threshold, and output a control command based on the comparison result. The first actuator is connected to the control module and is used to execute the first regulation command output by the control module when the curling temperature is higher than the first temperature threshold, thereby reducing the speed of the extrusion unit on the production line. The second actuator, connected to the control module, is used to execute the second regulation command output by the control module when the curling temperature is lower than the second temperature threshold, and to perform the action of reducing or cutting off the cooling medium supply to the cooling unit, wherein the first temperature threshold is greater than the second temperature threshold.

[0008] Specifically, the first control command is a deceleration command, and the first actuator is a frequency converter connected to the drive motor of the extrusion unit; The frequency converter executes the deceleration command to reduce the rotational speed of the extrusion unit according to a preset deceleration ratio.

[0009] Specifically, the second actuator is an on / off control valve installed on the inlet or return water pipe of the cooling unit; The second control command is a switching signal used to control the opening or closing of the on / off control valve to control the circulation supply of the cooling medium.

[0010] Specifically, the control module has a preset intermediate zone, which is located between the second temperature threshold and the first temperature threshold; When the curling temperature is within the intermediate zone, the control module does not generate the first control command or the second control command.

[0011] Specifically, the preset deceleration ratio is either a stepped deceleration ratio or a fixed percentage deceleration ratio.

[0012] Specifically, the second actuator is a continuous regulating valve installed on the inlet or return water pipe of the cooling unit; The second control command is an analog signal used to control the opening of the continuous regulating valve in order to continuously regulate the circulating supply of the cooling medium.

[0013] Specifically, the system also includes a manufacturing execution module, which is communicatively connected to the control module; The manufacturing execution module is used to configure the first temperature threshold and the second temperature threshold, and to receive and store the temperature data, speed data and valve status data uploaded by the control module, and to associate and bind the temperature data, speed data and valve status data with the current production order information.

[0014] According to a second aspect of the present invention, a method for controlling a calendering production line with coiling temperature feedback is provided, the method comprising: S100: Real-time continuous acquisition of the film winding temperature before winding and generation of temperature signal; S200: Receive the temperature signal, compare the temperature signal with a preset temperature threshold, and output a control command based on the comparison result; S300: When the curling temperature is higher than the first temperature threshold, the first actuator executes the first control command to reduce the speed of the extrusion unit of the production line. S400. When the curling temperature is lower than the second temperature threshold, the second actuator executes the second control command to control the cooling unit to reduce or cut off the supply of cooling medium, wherein the first temperature threshold is greater than the second temperature threshold.

[0015] Specifically, step S200 further includes: A preset warning threshold is provided, which is located between the first temperature threshold and the second temperature threshold. When the curling temperature reaches the warning threshold, a warning signal is generated and pushed to the human-machine interface.

[0016] According to a third aspect of the present invention, an electronic device is provided, comprising: a memory; and a processor, wherein the memory stores computer-readable instructions, which, when executed by the processor, implement the above-described method for controlling a calendering production line with coiling temperature feedback.

[0017] Beneficial effects: This invention provides a system and method for controlling the coiling temperature of a calendering production line, achieving precise and coordinated control of the coiling temperature. By setting up a temperature detection module to continuously monitor the coiling temperature in real time, it solves the lag of traditional manual sampling and provides a data foundation for precise control. The control module makes logical judgments based on preset temperature thresholds. When the coiling temperature exceeds the preset temperature threshold, it drives the first and second actuators respectively, forming a coordinated response mechanism of slowing down when the temperature is high and stopping the water flow when the temperature is low. This keeps temperature fluctuations within a very small range, further improving the product's dimensional stability and appearance quality, and greatly enhancing the intelligence, reliability, and usability of this invention. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the composition of the calendering production line control system with coiling temperature feedback provided in a specific embodiment of the present invention; Figure 2 This is a flowchart of the calendering production line control method with coiling temperature feedback provided in a specific embodiment of the present invention; Figure 3 This is an example workflow diagram of the calendering production line control method with coiling temperature feedback provided in a specific embodiment of the present invention. Detailed Implementation

[0019] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Based on the embodiments in this application, other similar embodiments obtained by those skilled in the art without creative effort should all fall within the scope of protection of this application. Furthermore, directional terms mentioned in the following embodiments, such as "up," "down," "left," and "right," are only for reference to the directions in the accompanying drawings; therefore, the directional terms used are for illustrative purposes and not for limiting the invention.

[0020] The present invention will be further described below with reference to the accompanying drawings and preferred embodiments.

[0021] Example 1 Please see Figure 1 This embodiment provides a calendering production line control system with coiling temperature feedback, including: The temperature detection module is installed in front of the winding station of the calendering production line to continuously detect the winding temperature of the film before winding in real time and generate a temperature signal. The control module, connected to the temperature detection module, is used to receive the temperature signal, compare the temperature signal with a preset temperature threshold, and output a control command based on the comparison result. The first actuator is connected to the control module and is used to execute the first regulation command output by the control module when the curling temperature is higher than the first temperature threshold, thereby reducing the speed of the extrusion unit on the production line. The second actuator, connected to the control module, is used to execute the second regulation command output by the control module when the curling temperature is lower than the second temperature threshold, and to perform the action of reducing or cutting off the cooling medium supply to the cooling unit, wherein the first temperature threshold is greater than the second temperature threshold.

[0022] It is understandable that this embodiment achieves precise and coordinated control of the coiling temperature in the calendering production line by constructing a complete closed-loop control system encompassing temperature detection, temperature judgment, and dual-mechanism execution. Compared with existing technologies, the temperature detection module can employ a fixed high-precision infrared temperature probe to achieve real-time continuous monitoring of the coiling temperature, changing the traditional intermittent sampling method using a handheld temperature gun, eliminating monitoring blind spots, and providing a real-time and reliable data foundation for precise control. Secondly, the control module incorporates dual-channel differentiated control logic, selecting the most appropriate control method based on the direction of temperature deviation. When the temperature is too high, it reduces heat input at the source and lowers the extrusion unit speed; when the temperature is too low, it cuts off the supply of cooling medium to reduce heat loss. This approach is both fast and effective, energy-efficient and gentle, avoiding quality problems such as shrinkage, adhesion, and deformation caused by temperature fluctuations.

[0023] It should be further explained that the aforementioned extrusion unit refers to the core equipment in the calendering production line used to plasticize, mix, and continuously convey the rubber compound to the calender. It typically includes the extruder main unit, drive motor, gearbox, and screw. The main function of the extrusion unit is to heat and melt the solid rubber compound, and then use the shearing action generated by the screw rotation to plasticize it uniformly. Finally, it supplies the compound to the subsequent calender rollers at a certain pressure and flow rate. The rotational speed of the extrusion unit determines the extrusion volume and shear heat per unit time, thus affecting the film temperature. In this embodiment, adjusting the rotational speed of the extrusion unit through the first actuator essentially controls the winding temperature from the source of heat generation. The aforementioned cooling unit refers to a combination of equipment installed after the calender and before the winding station for forced cooling of high-temperature film. It typically includes one or more cooling drums, cooling water circulation pipes, water pumps, cooling towers or chillers, etc. The film comes into contact with the surface of the cooling drum, which is filled with cooling medium. Through heat exchange, the heat carried by the film is carried away, reducing the film temperature to a suitable range for winding. The supply status of the cooling medium directly determines the cooling intensity. The flow of the cooling medium is controlled by a second actuator, which essentially adjusts the cooling intensity on demand according to the actual requirements of the winding temperature.

[0024] In this embodiment, the first control command is a deceleration command, and the first actuator is a frequency converter connected to the drive motor of the extrusion unit; the frequency converter executes the deceleration command to reduce the rotational speed of the extrusion unit according to a preset deceleration ratio.

[0025] It should be noted that this embodiment selects a frequency converter as the first actuator based on the heat generation mechanism. In the calendering production line, the main source of heat causing the film temperature to rise is the shear heat generated by the high-speed rotation of the extruder screw. Therefore, reducing the speed of the extrusion unit is the most direct and fastest way to reduce heat input at the source. The frequency converter can receive analog signals from the control module, such as 4-20mA current signals and 0-10V voltage signals, to achieve precise adjustment of the drive motor speed. Unlike the crude methods such as drastic speed reduction or emergency shutdown adopted by operators when the temperature is too high in the prior art, this embodiment uses a preset deceleration ratio for smooth fine-tuning, such as a speed reduction of 2%-5% each time. This gradual adjustment method can effectively suppress the temperature rise trend and avoid the impact of sudden speed changes on the uniformity of film thickness, thus maintaining the continuity of production to the maximum extent while ensuring quality. In addition, the frequency converter has a fast adjustment response speed, which can usually complete the speed adjustment in milliseconds, enabling timely suppression of temperature fluctuations.

[0026] In this embodiment, the second actuator is a cooling medium regulating valve installed on the inlet or return water pipe of the cooling unit; the second control command is a switching signal used to control the action of the cooling medium regulating valve to regulate the circulating supply of the cooling medium.

[0027] Specifically, the second actuator is an on / off control valve installed on the inlet or return water pipe of the cooling unit; the second control command is a switching signal used to control the opening or closing of the on / off control valve to control the circulation supply of the cooling medium.

[0028] In one specific embodiment, the second actuator can be a switch-on control valve, such as a pneumatic shut-off valve, controlled by a switching signal. This embodies the energy-saving concept of on-demand cooling. When the temperature is too low, it indicates over-cooling or excessive heat dissipation from the environment. In this case, the most effective method is not to start the heating device, but to stop external cooling and allow the system's own residual heat and ambient temperature to naturally recover. The pneumatic shut-off valve has the advantages of simple structure, rapid response, and low cost. It receives a switching signal from the control module to perform a fully open or fully closed action. Compared to the scheme of continuous adjustment using a proportional regulating valve, the switch-on control used in this embodiment, although sacrificing some control precision, is sufficient to meet the needs of cutting off the cooling medium supply in the case of excessively low temperatures, and significantly reduces system complexity and implementation costs. In practical applications, the pneumatic shut-off valve is usually equipped with a manual bypass for easy equipment maintenance and emergency operation. When the temperature returns to the normal range, i.e., the coiling temperature is greater than or equal to the second temperature threshold and less than or equal to the first temperature threshold, the control module can output a command to reopen the valve and restore the cooling medium supply.

[0029] Furthermore, the second actuator is a continuous regulating valve installed on the inlet or return water pipe of the cooling unit; the second control command is an analog signal used to control the opening of the continuous regulating valve to continuously regulate the circulation supply of the cooling medium.

[0030] In another specific embodiment, the second actuator can also be a continuous regulating valve, such as a proportional regulating valve, including an electric regulating valve or a pneumatic regulating valve, used to continuously adjust the supply of cooling medium according to the analog signal output by the control module. When the curling temperature is lower than the second temperature threshold but the deviation is small, the control module can output an adjustment command to reduce the valve opening of the proportional regulating valve, thereby reducing the flow of cooling medium and achieving gentle cooling. When the temperature is significantly lower than the second temperature threshold, the control module can output a full-close command to completely cut off the supply of cooling medium. Compared with the on-off control of the pneumatic shut-off valve, the proportional regulating valve can achieve more precise cooling intensity adjustment and is suitable for production scenarios with higher requirements for temperature control accuracy.

[0031] In some specific embodiments, the control module has a preset intermediate zone, which is located between the second temperature threshold and the first temperature threshold; when the curling temperature is within the intermediate zone, the control module does not generate the first control command or the second control command.

[0032] It should be noted that this embodiment introduces the concept of an intermediate zone. In actual production, due to the slight fluctuations in temperature detection and the time required for control system response, without an intermediate zone, when the temperature fluctuates near the first temperature threshold, the system may frequently issue and cancel deceleration commands, causing repeated adjustments to the extrusion unit speed. This not only affects equipment lifespan but also causes instability in the production line. Similarly, frequent valve opening and closing may occur near the second temperature threshold. By setting a non-action range between the two thresholds, when the temperature falls within this range, the control module maintains its current state and does not output control commands, effectively avoiding frequent system oscillations and excessive wear on the actuators. For example, the second temperature threshold can be set to 80°C, the first temperature threshold to 90°C, and the intermediate zone to be the range between 80-90°C. When the temperature fluctuates around 85°C, the system does not perform any control. Only when the temperature exceeds 90°C or falls below 80°C are the corresponding actions triggered. By adopting the above scheme, the accuracy of control and the stability of the system are further improved.

[0033] In some specific embodiments, the preset deceleration ratio is a stepped deceleration ratio or a fixed percentage deceleration ratio.

[0034] It should be noted that this embodiment provides two preferred deceleration methods to adapt to different production scenarios. A fixed percentage deceleration ratio is the simplest implementation. For example, each time the temperature exceeds the first temperature threshold, the speed is reduced by 3% of the current rotation speed. The advantage of this method is its simple logic and ease of implementation, making it suitable for the production of ordinary products that are not very sensitive to temperature fluctuations. A stepped deceleration ratio is more intelligent, dynamically adjusting the deceleration amount according to the degree of temperature exceedance. For example, when the temperature exceeds the first temperature threshold but not exceeds the first temperature threshold +5°C, the speed is reduced by 2%; when the temperature exceeds the first temperature threshold +5°C but not exceeds +10°C, the speed is reduced by 5%; when the temperature exceeds the first temperature threshold +10°C, the speed is reduced by 10%. This stepped deceleration allows for fine-tuning when the temperature slightly exceeds the limit, avoiding overreaction, and provides a rapid response when the temperature severely exceeds the limit, promptly suppressing the temperature rise trend. In addition, a PID control algorithm can be combined to make more precise speed adjustment based on the integral or derivative term of the temperature deviation. However, this requires more complex parameter tuning. Regardless of the deceleration strategy adopted, the core of this embodiment is to achieve temperature control by smooth deceleration rather than emergency shutdown, thereby maximizing the continuity of production.

[0035] In a preferred embodiment, the pneumatic shut-off valve is normally open or normally closed, and is used to perform the action of fully opening or fully closing the cooling unit according to the switching signal, so as to control the supply of cooling medium to the cooling unit.

[0036] It should be noted that this embodiment provides two options for the selection of pneumatic shut-off valves to adapt to different safety requirements. The normally open pneumatic shut-off valve is in the open state when there is no control signal, and the cooling medium flows normally. It is suitable for occasions where cooling priority needs to be ensured, such as when producing materials with strict upper temperature requirements. Even if the control system fails, the cooling system will still operate to prevent safety accidents caused by excessive temperature. The normally closed pneumatic shut-off valve is in the closed state when there is no control signal. It is suitable for occasions where energy saving priority needs to be ensured, such as when producing materials sensitive to the lower temperature limit. Even if the control system fails, the cooling system will not malfunction and cause the temperature to drop too low. In practical applications, a two-position two-way valve or a two-position three-way valve can also be selected according to process requirements. The former is used for simple on / off control, while the latter can be used to realize the bypass circulation of cooling water to avoid water pump pressure buildup when the main line is closed. Regardless of the valve type used, this embodiment adopts on / off control, which has significant advantages over proportional control valves, such as low cost, high reliability, and simple maintenance. It is especially suitable for harsh industrial environments.

[0037] In this embodiment, the system further includes a manufacturing execution module, which is communicatively connected to the control module. The manufacturing execution module is used to configure the first temperature threshold and the second temperature threshold, and to receive and store temperature data, rotation speed data and valve status data uploaded by the control module. At the same time, it associates and binds the temperature data, rotation speed data and valve status data with the current production order information.

[0038] It should be noted that this embodiment elevates the field control system to the level of a digital factory by introducing a manufacturing execution module, such as MES, thus solving the problem of data silos in traditional production. The Manufacturing Execution Module (MES) communicates with field control modules, such as PLCs, via industrial Ethernet or fieldbus to achieve bidirectional data exchange. Regarding parameter configuration, process engineers can easily set parameters such as the first temperature threshold, second temperature threshold, warning threshold, deceleration ratio, and delay time on the MES's human-machine interface. These parameters are then distributed to the control modules on each production line via the network, eliminating the need for on-site operation of each device and significantly improving process adjustment efficiency. For data acquisition, the control modules upload data such as temperature curves, speed changes, and valve action events in real time. The MES system associates and binds this data with information such as the current production order number, rubber batch number, operator, and production time, forming a complete electronic production record. When subsequent processes or customers report quality issues, technicians only need to enter the product batch number to quickly trace the complete process parameter curves during the production of that roll of film, accurately pinpointing the cause of the problem and providing data support for process optimization and quality improvement. Furthermore, the MES system can perform statistical analysis on historical data to identify weak points in temperature control, providing a basis for preventative maintenance decisions.

[0039] It should be noted that this embodiment provides a calendering production line control system with coiling temperature feedback, including a temperature monitoring module, a control module, a first actuator, and a second actuator. By constructing a complete closed-loop control system of temperature detection, temperature judgment, and dual-mechanism execution, precise and coordinated control of the coiling temperature of the calendering production line is achieved. This system not only solves the problems of monitoring lag, rough control, and energy waste inherent in traditional manual operation, but also realizes digital management of process parameters and full-process quality traceability by introducing a manufacturing execution module, significantly improving the intelligence level of the production process and the stability of product quality. Compared with existing technologies, this embodiment has multiple advantages such as precise control, rapid response, energy saving and consumption reduction, and data traceability, providing a complete technical solution for the intelligent upgrading of calendering production lines.

[0040] Example 2 Please see Figure 2 This embodiment provides a method for controlling a calendering production line with coiling temperature feedback, the method comprising: S100: Real-time continuous acquisition of the film winding temperature before winding and generation of temperature signal; S200: Receive the temperature signal, compare the temperature signal with a preset temperature threshold, and output a control command based on the comparison result; S300: When the curling temperature is higher than the first temperature threshold, the first actuator executes the first control command to reduce the speed of the extrusion unit of the production line. S400. When the curling temperature is lower than the second temperature threshold, the second actuator executes the second control command to control the cooling unit to reduce or cut off the supply of cooling medium, wherein the first temperature threshold is greater than the second temperature threshold.

[0041] It is understood that the method provided in this embodiment corresponds to the system in Embodiment 1. It achieves automatic closed-loop control of the curling temperature through a programmed control flow. Step S100 uses a fixed infrared temperature probe to continuously detect the curling temperature, solving the problems of data sparsity and lag in manual sampling. Step S200 uses a control module, such as a PLC or industrial computer, to execute temperature comparison logic and compare the real-time temperature with multiple preset thresholds. This step transforms manual operation experience into quantifiable and programmable rules. Steps S300 and S400 correspond to differentiated responses for high and low temperature conditions, respectively: when the temperature is too high, the speed of the extrusion unit is smoothly reduced by the frequency converter to reduce heat input from the source; when the temperature is too low, the cooling water is shut off by a pneumatic shut-off valve to block heat loss. This dual-channel collaborative control strategy can balance control effect and energy efficiency. By executing the above steps, this method can greatly reduce the fluctuation range of the curling temperature, further improve product consistency and yield, and achieve multiple optimizations in quality, efficiency, and energy consumption.

[0042] In this embodiment, step S200 further includes: setting a preset warning threshold, the warning threshold being located between the first temperature threshold and the second temperature threshold; when the curling temperature reaches the warning threshold, generating a warning signal and pushing it to the human-computer interaction interface.

[0043] It should be further explained that the warning threshold is an independent intermediate threshold used for warning purposes. The warning threshold is typically set between a first temperature threshold and a second temperature threshold (including cases where it is set to either the first or second temperature threshold). The first temperature threshold is greater than the second temperature threshold; for example, it can be lower than the first temperature value but close to a certain value. For instance, if the first temperature threshold is 90°C, the warning threshold could be set to 85°C. When the temperature continues to rise to 85°C, even before automatic deceleration control is triggered, the system will generate a warning signal, notifying operators to pay attention to abnormal temperature trends through various means such as on-site audible and visual alarms, operator station pop-ups, and SMS messages. After receiving the warning, operators can perform preventative checks, such as cleaning dust from the infrared sensor's mirror (the sensor has a blower but may still be clogged), checking the cooling water pressure and temperature, and observing the extruder's operating status, thus eliminating potential problems in their early stages. This warning mechanism not only reduces the frequency of automatic control intervention and extends the lifespan of the actuators, but more importantly, it cultivates operators' data awareness and preventative maintenance habits, achieving intelligent production through human-machine collaboration. Similarly, for low-temperature operating conditions, corresponding low-temperature warning thresholds can be set to remind operators to pay attention to potential issues such as excessively low ambient temperatures or over-cooling. The specific values ​​of the warning thresholds can be flexibly configured according to the process requirements of different rubber compound formulations and centrally managed through the MES system.

[0044] Furthermore, the warning threshold in this embodiment is typically set for overheating conditions. In actual production, excessively high temperatures are the primary factor leading to quality problems such as film shrinkage and adhesion. Those skilled in the art can also set a low-temperature warning threshold according to actual needs. In this case, the low-temperature warning threshold should be set in the region above and close to the second temperature threshold to provide early warning of the risk of overcooling. The setting of the warning threshold provides operators with an opportunity to intervene in advance without triggering automatic control. This mechanism can significantly reduce the frequency of automatic control intervention and extend the service life of actuators such as frequency converters and pneumatic shut-off valves. In practical applications, the specific value of the warning threshold can be flexibly configured according to the process requirements of different adhesive formulations and centrally managed and distributed through the MES system to ensure the standardization and traceability of process parameters.

[0045] See Figure 3 The working principle of this invention will be illustrated below with specific examples: Taking a rubber calendering production line as an example, this production line mainly produces industrial rubber sheets with a thickness of 1.5mm. The rubber compound is ethylene propylene diene monomer (EPDM). According to the process requirements, the optimal winding temperature during winding is 85±5°C. Therefore, the first temperature threshold (high temperature control threshold) is set to 90°C, the second temperature threshold (low temperature control threshold) is set to 80°C, the warning threshold is set to 88°C, and the intermediate zone is 80-90°C. A fixed percentage deceleration ratio is adopted, with a deceleration of 3% each time.

[0046] During normal production, the temperature detection module can use an OPTCTL infrared thermometer with a response time of 10ms to monitor the surface temperature of the film before winding in real time. The temperature signal is transmitted to the PLC control module in the form of a 4-20mA analog signal. When the temperature is stable at around 85°C, it is in the intermediate zone. The PLC does not output any control commands, the extrusion unit runs stably at the set speed, the cooling water pneumatic shut-off valve remains open, and the cooling drum is normally circulated with water. At a certain moment, due to slight fluctuations in the extruder feed or an increase in ambient temperature, the coiling temperature begins to rise slowly. When the temperature reaches the 88°C warning threshold, the PLC triggers the warning logic, and a yellow warning prompt box pops up on the MES operation station interface. At the same time, a warning text message is sent to the staff, such as: "The coiling temperature of the calender line has reached 88°C. Please pay attention." After receiving the warning information, the operator views the real-time temperature curve through the MES interface and checks whether the infrared probe purger is working properly. After confirming that the probe is free of contamination, the operator continues to observe the temperature trend. If the temperature continues to rise and exceeds the first temperature threshold of 90°C, the PLC immediately executes a deceleration command, sending a signal to the extrusion unit frequency converter through the analog output module to reduce the speed from 50 rpm to 48.5 rpm, which is a 3% reduction. After deceleration, the heat input is reduced, and the temperature rise trend is suppressed. After about 2 minutes of stable operation, the temperature gradually drops back to below 88°C. The PLC maintains the current speed unchanged and continues to monitor temperature changes. During another production period, due to excessively low cooling water temperature or a brief shutdown followed by restart of the production line, the curling temperature dropped to 78°C, below the second temperature threshold of 80°C. Upon detecting the low temperature condition, the PLC immediately output a DO signal to the solenoid valve of the pneumatic shut-off valve, closing the cooling water inlet valve. After the cooling water was interrupted, the cooling drum gradually warmed up by relying on its own heat capacity and the heat transferred by the film. When the temperature rose to 82°C, it entered the intermediate zone. The PLC then output a DO signal again to open the valve and restore the cooling water supply. Throughout the entire process, the extrusion unit speed remained stable, and the production line was not subjected to any impact.

[0047] All the process data mentioned above, including temperature curves, speed changes, valve action times, and early warning / alarm events, are uploaded to the MES system in real time by the PLC. This data is automatically linked to the current production order number, rubber batch number, and operator ID. If, after a period of time, the quality department reports a slight shrinkage issue in this batch of products, process engineers can use the MES system to trace back the entire process parameters during the production of that order. They will find that the temperature reached 91°C within a short period. Combined with the rubber batch information, the issue is ultimately identified as a change in heat sensitivity caused by fluctuations in the raw material batch, providing precise data support for formula adjustments.

[0048] It should be noted that this embodiment provides a method for controlling a calendering production line with coiling temperature feedback. Through a control process involving real-time monitoring, intelligent decision-making, and dual-channel collaborative execution, precise closed-loop control of the coiling temperature is achieved. This method not only automatically responds to temperature fluctuations during production, stabilizing key process parameters within the target range, but also enables early detection and handling of problems through an early warning mechanism, and provides a basis for continuous improvement through data traceability. Compared with existing manual operation methods, this method significantly reduces reliance on operator experience, making tacit knowledge explicit and procedural, and providing a reliable technical means for the standardized, intelligent, and digital operation of calendering production lines.

[0049] Example 3 In a preferred embodiment, this application also provides an electronic device, the electronic device comprising: The computer device includes a memory and a processor. The memory stores computer-readable instructions that, when executed by the processor, implement the described method for controlling a calendering production line with coiling temperature feedback. This computer device can be broadly categorized as a server, terminal, or any other electronic device with the necessary computing and / or processing capabilities. In one embodiment, the computer device may include a processor, memory, network interface, communication interface, etc., connected via a system bus. The processor of the computer device can be used to provide the necessary computing, processing, and / or control capabilities. The memory of the computer device may include a non-volatile storage medium and internal memory. The non-volatile storage medium may store an operating system, computer programs, etc. The internal memory can provide an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The network interface and communication interface of the computer device can be used to connect and communicate with external devices via a network. When the computer program is executed by the processor, it performs the steps of the method of the present invention.

[0050] It is understood that the electronic device provided in this embodiment can serve as the control module in the above embodiments, deployed on the calendering production line or in the central control room. This electronic device executes the control method described in Embodiment 2 by running computer-readable instructions stored in its memory, realizing functions such as signal acquisition from the temperature detection module, instruction output to the actuator, and data interaction with the manufacturing execution module. In practical applications, this electronic device can be a PLC, an industrial control computer, an embedded controller, or a general-purpose computer configured with corresponding software. By embedding the control logic of this invention into the electronic device in the form of a computer program, standardized replication and rapid deployment of the technical solution are achieved, reducing implementation costs and improving the maintainability and scalability of the system. Furthermore, this electronic device can connect to multiple production lines via a network to achieve centralized monitoring and remote operation and maintenance, further improving production management efficiency.

[0051] This invention can be implemented as a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, causes the steps of the methods of embodiments of the invention to be performed. In one embodiment, the computer program is distributed across multiple network-coupled computer devices or processors, such that the computer program is stored, accessed, and executed in a distributed manner by one or more computer devices or processors. A single method step / operation, or two or more method steps / operations, may be executed by a single computer device or processor or by two or more computer devices or processors. One or more method steps / operations may be executed by one or more computer devices or processors, and one or more other method steps / operations may be executed by one or more other computer devices or processors. One or more computer devices or processors may execute a single method step / operation, or execute two or more method steps / operations.

[0052] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0053] The technical features described above can be combined arbitrarily. Although not all possible combinations of these technical features are described, any combination of these technical features should be considered to be covered by this specification, provided that such combination does not contain contradictions.

[0054] The specific embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any other corresponding changes and modifications made in accordance with the technical concept of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A calendering production line control system with coiling temperature feedback, characterized in that, include: The temperature detection module is installed in front of the winding station of the calendering production line to continuously detect the winding temperature of the film before winding in real time and generate a temperature signal. The control module, connected to the temperature detection module, is used to receive the temperature signal, compare the temperature signal with a preset temperature threshold, and output a control command based on the comparison result. The first actuator is connected to the control module and is used to execute the first regulation command output by the control module when the curling temperature is higher than the first temperature threshold, thereby reducing the speed of the extrusion unit on the production line. The second actuator, connected to the control module, is used to execute the second regulation command output by the control module when the curling temperature is lower than the second temperature threshold, and to perform the action of reducing or cutting off the cooling medium supply to the cooling unit, wherein the first temperature threshold is greater than the second temperature threshold.

2. The calendering production line control system with coiling temperature feedback according to claim 1, characterized in that, The first control command is a deceleration command, and the first actuator is a frequency converter connected to the drive motor of the extrusion unit; The frequency converter executes the deceleration command to reduce the rotational speed of the extrusion unit according to a preset deceleration ratio.

3. The calendering production line control system with coiling temperature feedback according to claim 1, characterized in that, The second actuator is an on / off control valve installed on the inlet or return water pipe of the cooling unit; The second control command is a switching signal used to control the opening or closing of the on / off control valve to control the circulation supply of the cooling medium.

4. The calendering production line control system with coiling temperature feedback according to claim 1, characterized in that, The control module has a preset intermediate zone, which is located between the second temperature threshold and the first temperature threshold. When the curling temperature is within the intermediate zone, the control module does not generate the first control command or the second control command.

5. The calendering production line control system with coiling temperature feedback according to claim 2, characterized in that, The preset deceleration ratio is either a stepped deceleration ratio or a fixed percentage deceleration ratio.

6. The calendering production line control system with coiling temperature feedback according to claim 1, characterized in that, The second actuator is a continuous regulating valve installed on the inlet or return water pipe of the cooling unit; The second control command is an analog signal used to control the opening of the continuous regulating valve in order to continuously regulate the circulating supply of the cooling medium.

7. The calendering production line control system with coiling temperature feedback according to claim 1, characterized in that, The system also includes a manufacturing execution module, which is communicatively connected to the control module. The manufacturing execution module is used to configure the first temperature threshold and the second temperature threshold, and to receive and store the temperature data, speed data and valve status data uploaded by the control module, and to associate and bind the temperature data, speed data and valve status data with the current production order information.

8. A method for controlling a calendering production line with coiling temperature feedback, applied to the calendering production line control system with coiling temperature feedback as described in any one of claims 1-7, characterized in that, include: S100: Real-time continuous acquisition of the film winding temperature before winding and generation of temperature signal; S200: Receive the temperature signal, compare the temperature signal with a preset temperature threshold, and output a control command based on the comparison result; S300: When the curling temperature is higher than the first temperature threshold, the first actuator executes the first control command to reduce the speed of the extrusion unit of the production line. S400. When the curling temperature is lower than the second temperature threshold, the second actuator executes the second control command to control the cooling unit to reduce or cut off the supply of cooling medium, wherein the first temperature threshold is greater than the second temperature threshold.

9. The method for controlling a calendering production line with coiling temperature feedback according to claim 8, characterized in that, Step S200 further includes: A preset warning threshold is provided, which is located between the first temperature threshold and the second temperature threshold. When the curling temperature reaches the warning threshold, a warning signal is generated and pushed to the human-machine interface.

10. An electronic device, characterized in that, include: Memory; The processor, wherein the memory stores computer-readable instructions that, when executed by the processor, implement the rolling production line control method for coiling temperature feedback according to any one of claims 8 to 9.

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