An automatic feeding control system and method for macromolecular plasticizer in cable sheath preparation

Abstract

The application provides a cable sheath preparation high-molecular plasticizer automatic feeding control system and method, which comprises a temperature sensor module for collecting multi-point temperature data of materials in real time, outputting T, v and Gt after preprocessing; a data processing module electrically connected with the temperature sensor module, which is provided with a plasticization adaptation coefficient calculation unit, the plasticization adaptation coefficient calculation unit calculates a plasticization adaptation coefficient S based on T, v and Gt; and a feeding control module electrically connected with the data processing module and a high-molecular plasticizer feeding device, which dynamically adjusts a real-time feeding rate V based on S, realizes temperature self-adaptive precise control of high-molecular plasticizer feeding, guarantees sufficient plasticization of the high-molecular plasticizer, improves cable sheath plasticization uniformity and preparation process stability, and ensures that the finished product meets the application requirements of high-acid and high-alkali resistance, high-frequency torsion and super flexibility.

Description

Technical Field

[0001] This invention relates to the field of intelligent control technology for polymer material processing, and in particular to an automatic feeding control system and method for polymer plasticizers in cable sheath preparation. It is applicable to the high-speed mixing and preparation process of PVC cable sheaths that are resistant to high acids and alkalis, high frequency torsion, and ultra-flexible. It achieves precise and intelligent control of the core process pain point of polymer plasticizer feeding after formula adjustment. Background Technology

[0002] In the preparation of PVC cable sheaths resistant to high acids, alkalis, and high-frequency torsion, the polymeric plasticizer added to the formula is the core component ensuring the cable sheath's ultra-flexibility and resistance to torsional fatigue. The formula also includes 17 parts of nano-calcium to enhance corrosion resistance and bending resistance, while environmentally friendly and efficient stabilizers ensure product durability. This process imposes strict temperature and time constraints on the addition of the polymeric plasticizer: the plasticizer must be precisely added when the material temperature reaches 110℃, and a sufficient constant temperature of 110~120℃ must be maintained after addition for a sufficient plasticizing time. Because the plasticizing rate of polymeric plasticizers is much slower than that of conventional plasticizers, only by ensuring a sufficient constant temperature plasticizing time can full plasticization be achieved. Simultaneously, the environmentally friendly and efficient stabilizer degrades at 125℃, and the plasticizer is easily volatilized at high temperatures; therefore, the material temperature must not exceed 125℃, otherwise it will directly lead to a significant decrease in the cable sheath's corrosion resistance and flexibility.

[0003] In actual feeding, nano-calcium preferentially adsorbs polymeric plasticizers and conventional plasticizers, easily causing localized "plasticization deficiency" in the material, forming a significant temperature gradient, and leading to drastic temperature fluctuations. Existing polymeric plasticizer feeding methods often use fixed rates and fixed times, without linkage to the real-time temperature of the material. This makes it impossible to adjust the feeding rate according to temperature fluctuations and gradients, easily leading to two problems: First, feeding too quickly intensifies nano-calcium adsorption, further expanding localized plasticization deficiency and temperature gradients, even causing temperatures to exceed threshold values; second, feeding too slowly fails to complete the feeding within the process time, and the isothermal plasticization time is insufficient, resulting in incomplete plasticization of the polymeric plasticizer and substandard cable sheath flexibility.

[0004] Furthermore, existing feeding systems mostly use single-point temperature detection, which cannot reflect the overall temperature state and temperature gradient of the material, resulting in a high rate of control misjudgment. Moreover, they lack a closed-loop linkage protection mechanism between temperature and feeding, and cannot quickly stop feeding and trigger cooling when the temperature exceeds the threshold, which can easily cause stabilizer degradation and plasticizer volatilization. Existing technologies cannot adapt to the process requirements after formula adjustment, and it is difficult to solve the problems of slow plasticization of polymer plasticizers and temperature instability caused by nano-calcium adsorption, which restricts the stability of cable sheath preparation process and the consistency of product performance.

[0005] Therefore, those skilled in the art need to improve existing processes and systems to overcome the aforementioned deficiencies. Summary of the Invention

[0006] This invention provides an automatic feeding control system for polymer plasticizers in cable sheath preparation. It solves the core technical problems of slow plasticization of polymer plasticizers after formula adjustment requiring constant temperature and pressure, degradation of stabilizers or volatilization of plasticizers due to temperature exceeding the threshold, and temperature gradients and uneven plasticization caused by nano-calcium adsorption. It achieves adaptive and precise temperature control of polymer plasticizer feeding, ensuring full plasticization of polymer plasticizers, improving the plasticization uniformity and preparation process stability of cable sheaths, and ensuring that the finished product meets the application requirements of high acid and alkali resistance, high frequency torsion, and ultra-flexibility.

[0007] To achieve the above objectives, in a first aspect, this application provides an automatic feeding control system for polymeric plasticizers in cable sheath preparation, comprising: The temperature sensor module is installed in the material chamber of the high-speed mixer to collect multi-point temperature data of the material in real time, and outputs the average real-time temperature T, heating rate v and temperature gradient value Gt after preprocessing. The data processing module is electrically connected to the temperature sensor module and has a plasticizing compatibility coefficient calculation unit. The plasticizing compatibility coefficient calculation unit calculates the plasticizing compatibility coefficient S based on the material's average real-time temperature T, the heating rate v, and the temperature gradient value Gt. The feeding control module is electrically connected to the data processing module and the polymer plasticizer feeding device, respectively. It dynamically adjusts the real-time feeding rate V of the polymer plasticizer feeding device based on the plasticization adaptation coefficient S.

[0008] Optionally, the temperature sensor module includes at least five sets of temperature sensors evenly distributed at the front, rear, left, right and center positions of the material chamber of the high-speed mixer, and has a built-in data preprocessing unit. The data preprocessing unit is configured to: calculate the average real-time temperature T of the material by multi-point temperature average, calculate the temperature rise rate v by the change of T per unit time, and calculate the temperature gradient value Gt by the maximum deviation between the temperature at each point and T.

[0009] Optionally, when the average real-time temperature T of the material is within the range of 110℃-120℃, the plasticizing adaptation coefficient S = 1 - (k1 × |T - T0| + k2 × v + k3 × Gt), where T0 is the reference plasticizing temperature in the process range of 110~120℃, k1 is the temperature deviation weighting coefficient, k2 is the temperature rise rate weighting coefficient, k3 is the temperature gradient weighting coefficient, and k1 + k2 + k3 = 1. When the average real-time temperature T of the material deviates from the range of 110℃-120℃, S = λ - λ (k1 × |T - T0| + k2 × v + k3 × Gt), where λ is the attenuation coefficient.

[0010] Optionally, a rate adjustment unit and a duration control unit are built in the feeding control module. The rate adjustment unit is configured to: preset a reference feeding rate V0 of the polymer plasticizer, and calculate the real-time feeding rate V according to the formula V = V0×S. The duration control unit is configured to: when the average real-time temperature T of the material is within the range of 110°C - 120°C, accumulate the constant-temperature plasticization duration. When the accumulated duration reaches the process preset value and the feeding is completed, a plasticization completion signal is triggered. When the average real-time temperature T of the material deviates from the range of 110°C - 120°C, the accumulation of the constant-temperature plasticization duration is paused, and the accumulation of the constant-temperature plasticization duration continues until the average real-time temperature T of the material drops back within this range.

[0011] Optionally, a safety protection module is further included, which is electrically connected to the temperature sensor module, the feeding control module, and the temperature control unit of the high-speed mixer respectively, and is configured to: set multiple levels of temperature safety thresholds, and perform hierarchical speed regulation, feeding pause, and cooling linkage intervention for the feeding of the polymer plasticizer.

[0012] Optionally, a threshold determination unit and a linkage execution unit are built in the safety protection module. The threshold determination unit is configured to: set three levels of temperature thresholds, including a reference plasticization temperature T0 = 115°C, a first-level warning threshold T1 = 120°C, and a second-level protection threshold T2 = 125°C. The hierarchical speed regulation strategy of the linkage execution unit is: when T ≤ T1 and T ≥ 110°C, the feeding rate is normally dynamically adjusted according to the plasticization adaptation coefficient S; when T1 < T < T2, control the feeding control module to reduce the real-time feeding rate V to 0.3V0 - 0.5V0, and at the same time control the cooling temperature of the temperature control unit of the high-speed mixer to be 35 - 40°C; when T ≥ T2, control the feeding control module to pause the feeding of the polymer plasticizer, and control the cooling temperature of the temperature control unit of the high-speed mixer to be 20 - 30°C; when T < 110°C, control the feeding control module to pause the feeding, and control the temperature control unit of the high-speed mixer to heat until T rises to 110°C and then resume the feeding.

[0013] Optionally, the polymer plasticizer feeding device is a variable-frequency metering pump.

[0014] To achieve the above object, in a second aspect, the present application provides a method for automatically controlling the feeding of a polymer plasticizer in the preparation of cable skins, including the following steps: S1. When the temperature of the material in the high-speed mixer rises to 110°C, a feeding start signal is triggered, and the temperature sensor module starts to collect the multi-point temperature data of the material in real time. After preprocessing, T, v, and Gt are output and synchronized to the data processing module and the safety protection module; S2. The data processing module receives T, v, and Gt, determines whether T is within the process range of 110 - 120°C, calculates the plasticization adaptation coefficient S according to the corresponding rules, and transmits the plasticization adaptation coefficient S to the feeding control module in real time; S3. The feeding control module receives the plasticizing adaptation coefficient S, calculates the real-time feeding rate V based on the preset benchmark feeding rate V0, and drives the polymer plasticizer feeding device to start feeding according to V. At the same time, the duration control unit starts the accumulation of constant temperature plasticizing time at 110~120℃. S4, the safety protection module monitors T in real time and determines the temperature status according to the three-level temperature threshold. If T deviates from the process range or exceeds the threshold, it will perform graded speed adjustment, pause feeding and cooling / heating linkage intervention until T returns to the process range. Then, according to S, it will resume feeding at the corresponding rate and continue to accumulate the constant temperature plasticizing time. S5. Repeat steps S1-S4 until the amount of polymer plasticizer added reaches the preset process value, and the cumulative constant temperature plasticizing time of 110~120℃ in the time control unit reaches the preset process value, trigger the feeding completion signal, and stop the feeding of polymer plasticizer.

[0015] Optionally, in step S5, if the constant temperature plasticizing time does not reach the preset process value after the material feeding is completed, the linkage cooling / heating unit of the safety protection module will stabilize T at 110~120℃ until the cumulative time reaches the target.

[0016] Optionally, the cable sheath comprises, by weight, 37 parts PVC resin, 27 parts dioctyl terephthalate, 10 parts trioctyl trimellitate, 3 parts polymer plasticizer, 3 parts stabilizer, 17 parts nano-activated calcium carbonate, 0.3 parts calcium stearate, 0.3 parts paraffin wax, and 2.4 parts antioxidant. In its preparation, the 37 parts PVC resin, 27 parts dioctyl terephthalate, 3 parts stabilizer, 17 parts nano-activated calcium carbonate, 0.3 parts calcium stearate, and 0.3 parts paraffin wax are first mixed. When heated to 90°C, 10 parts trioctyl trimellitate and 2.4 parts antioxidant are added and mixed. When heated to 110°C, 3 parts polymer plasticizer are added and mixed.

[0017] The present invention provides an automatic feeding control system and method for polymer plasticizers in cable sheath preparation, which, compared with the prior art, has the following advantages: 1. Design a plasticizing compatibility coefficient S, which comprehensively integrates temperature deviation, temperature rise rate, and temperature gradient to accurately characterize the compatibility of materials with polymer plasticizers in plasticizing. This enables dynamic adjustment of the positive correlation between the feeding rate and the S value, thereby alleviating local plasticization deficiencies caused by nano-calcium adsorption and improving the uniformity of material plasticization. 2. The designed time control unit only accumulates the effective plasticizing time of 110~120℃. After the material is added, it can trigger constant temperature and pressure to ensure that the polymer plasticizer is fully plasticized, and completely solve the problem of cable sheath flexibility not meeting the standard due to slow plasticization and insufficient time. 3. Three temperature thresholds are set, and a dual protection mechanism of "graded material feeding control + cooling / heating linkage intervention" is used. The cooling unit is connected by a hard wire to achieve millisecond-level response, strictly controlling the material temperature within the core range of 110~120℃. This effectively avoids stabilizer degradation and plasticizer volatilization caused by temperatures exceeding 125℃, ensuring the corrosion resistance and durability of the cable sheath. Attached Figure Description

[0018] The accompanying drawings, which form part of this application, are used to provide a further understanding of the application and to make other features, objects, and advantages of the application more apparent. The illustrative embodiments and descriptions of this application are used to explain the application and do not constitute an undue limitation of the application. In the drawings: Figure 1 This is a flowchart of the present invention. Detailed Implementation

[0019] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0020] 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 for the embodiments of this application 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.

[0021] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0022] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0023] In addition, the term "multiple" should mean two or more.

[0024] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0025] The cable sheath of the present invention comprises, by weight, 37 parts PVC resin, 27 parts dioctyl terephthalate, 10 parts trioctyl trimellitate, 3 parts polymer plasticizer, 3 parts stabilizer, 17 parts nano-activated calcium carbonate, 0.3 parts calcium stearate, 0.3 parts paraffin wax, and 2.4 parts antioxidant. In its preparation, the 37 parts PVC resin, 27 parts dioctyl terephthalate, 3 parts stabilizer, 17 parts nano-activated calcium carbonate, 0.3 parts calcium stearate, and 0.3 parts paraffin wax are first mixed. When heated to 90°C, 10 parts trioctyl trimellitate and 2.4 parts antioxidant are added and mixed. When heated to 110°C, 3 parts polymer plasticizer are added and mixed.

[0026] In the comparative example, the cable sheath, by weight, comprises: 47.2 parts PVC resin, 23.6 parts dioctyl phthalate, 5.9 parts trioctyl trimellitate, 3.5 parts calcium-zinc stabilizer, 17.6 parts heavy calcium carbonate, 0.4 parts calcium stearate, 0.4 parts paraffin wax, and 1.4 parts antioxidant.

[0027] The cable performance test data of this embodiment are compared with those of the comparative example as follows:

[0028] Compared with the comparative example, this embodiment adds a high-molecular-weight plasticizer to the plasticizer system, which significantly improves the elongation at break and migration resistance, and is the core of achieving ultra-flexibility and high torsional life; the comparative example only uses ordinary plasticizer, and the flexibility and fatigue life are obviously insufficient.

[0029] Nano-activated calcium, with a particle size of 50-100 nm, is used instead of heavy calcium in the filling system. Modified with an aluminate / titanium ester coupling agent, rather than unmodified nano-calcium, the nano-calcium, with its small particle size and high dispersibility, forms a continuous and dense micro-nano-level physical barrier inside the PVC sheath. This effectively blocks the penetration and diffusion of acidic and alkaline media, delaying the contact reaction between the media and the PVC molecular chains and plasticizers. Simultaneously, its surface activation layer, composed of non-polar groups, reduces the wettability of acidic and alkaline media on the sheath surface, minimizing media adsorption. Experiments show that after immersion in a 5% HCl / NaOH solution for 72 hours, the mechanical properties of the nano-calcium-filled cable sheath retain ≥90%, while that of the ordinary calcium-filled system is only about 70%, significantly improving the cable's durability in harsh corrosive environments.

[0030] However, after the addition of polymeric plasticizers, a sufficient constant temperature of 110-120℃ must be maintained for plasticizing time. This is because the plasticizing rate of polymeric plasticizers is much slower than that of conventional plasticizers. Only by ensuring a constant temperature plasticizing time can full plasticization be achieved. At the same time, environmentally friendly and efficient stabilizers will degrade at 125℃, and plasticizers are prone to volatilization at high temperatures. The material temperature must not exceed 125℃, otherwise it will directly lead to a significant decrease in the corrosion resistance and flexibility of the cable sheath. Moreover, at the same time, nano-calcium will preferentially adsorb polymeric plasticizers and conventional plasticizers, which can easily cause local "plasticization deficiency" in the material, forming a significant temperature gradient and causing drastic temperature fluctuations. Therefore, adaptive and precise control of the temperature of polymeric plasticizer addition is particularly important for improving product performance.

[0031] like Figure 1 As shown, an automatic feeding control system for polymer plasticizers in cable sheath preparation is disclosed. This system is adapted to the high-speed mixing and preparation process of PVC cable sheaths containing nano-calcium, conventional plasticizers, polymer plasticizers, and environmentally friendly, high-efficiency stabilizers. The core requirements of the process are precise addition at 110℃, constant temperature plasticization at 110~120℃, and a temperature strictly prohibited from exceeding 125℃. The system consists of a temperature sensor module, a data processing module, a feeding control module, and a safety protection module. Each module functions independently yet works in synergy to form a forced closed-loop data flow, achieving real-time linkage control of feeding and temperature. The following provides a detailed description of each module: I. Temperature Sensor Module As the detection module of the system, its core function is to accurately, in real time, and comprehensively capture the temperature status of materials, overcoming the limitations of single-point detection. The module includes at least 5 sets of high-precision PT100 temperature sensors, which are evenly distributed in five positions: front, back, left, right, and center of the material chamber of the high-speed mixer. It can simultaneously detect the temperature of different areas of the material and effectively capture the temperature gradient caused by the adsorption of nano-calcium. The sensor sampling accuracy is ≥ ±0.05℃ and the sampling interval is ≤0.5s, meeting the process requirements for high precision and high real-time performance of temperature detection.

[0032] The module is built with a data pre - processing unit. Without external calculation, it directly processes multi - point temperature data in real - time and outputs three core parameters, including: the average real - time temperature T of the material: the average value of multi - point temperatures, reflecting the overall temperature state of the material; the temperature rise rate v (℃ / min): the change amount of T per unit time, reflecting the trend of the material temperature change; the temperature gradient value Gt: the maximum deviation value between the temperature at each point and T, reflecting the degree of local temperature non - uniformity of the material. The pre - processed T, v, and Gt are synchronized to the data - processing module and the safety - protection module in real - time through the 485 bus, providing a reliable data basis for subsequent quantification and regulation.

[0033] II. Data - processing module As the calculation module of the system, its core function is to quantify the adaptability between the temperature state of the material and the plasticization of the polymer plasticizer. The module communicates with the temperature - sensor module through industrial Ethernet. It is built with a plasticization adaptability coefficient calculation unit, with pre - designed calculation formulas and weight parameters. After receiving T, v, and Gt transmitted by the temperature - sensor module, according to whether the material temperature is within the process range of 110 - 120℃, it generates the plasticization adaptability coefficient S using a differential calculation rule.

[0034] The plasticization adaptability coefficient S is the core index characterizing the temperature stability of the material and the adaptability of the polymer plasticizer. The value of S is negatively correlated with the temperature deviation, temperature rise rate, and temperature gradient. That is, the closer the S value is to 1, the more stable the material temperature, the smaller the temperature gradient, and the more suitable it is for the plasticization requirements of the polymer plasticizer; the smaller the S value, the greater the temperature fluctuation of the material, the more obvious the gradient, and the poor plasticization adaptability, and the feeding rate needs to be slowed down.

[0035] To adapt to the process requirements, the calculation rule of S is set as: When the average real - time temperature T of the material is within the range of 110℃ - 120℃, the plasticization adaptability coefficient S = 1-(k1×∣T - T0∣+k2×v + k3×Gt), where T0 is the reference plasticization temperature in the process range of 110 - 120℃, and T0 = 115℃ is the optimal plasticization temperature in the process, k1 = 0.3 is the temperature - deviation weight coefficient, k2 = 0.25 is the temperature - rise - rate weight coefficient, k3 = 0.45 is the temperature - gradient weight coefficient, and k1 + k2 + k3 = 1. When the average real - time temperature T of the material deviates from the range of 110℃ - 120℃, S = λ-λ(k1×∣T - T0∣+k2×v + k3×Gt), where λ = 0.5 is the attenuation coefficient, which significantly reduces the S value, indicating a significant decline in plasticization adaptability and triggering subsequent rate reduction or suspension of feeding. The value range of S is limited to 0 < S ≤ 1 to ensure the rationality of subsequent rate calculation.

[0036] III. Feeding - control module As the system's execution and control end, its core function is to dynamically adjust the feeding rate based on the plasticizing compatibility coefficient S, while ensuring a constant temperature plasticizing time of 110~120℃. The module communicates with the data processing module and the polymer plasticizer feeding device (variable frequency metering pump), and has a built-in rate adjustment unit and duration control unit. The two units work together to ensure that the feeding rate is adapted to the material's plasticizing rhythm and that the polymer plasticizer is fully plasticized.

[0037] Specifically, it includes a rate adjustment unit that presets a baseline feeding rate V0 for the polymer plasticizer and calculates the real-time feeding rate V using the formula V=V0×S. V and S are strictly positively correlated, and to avoid feeding too fast or too slow, the range of V is limited to 0.3V0≤V≤V0. The rate adjustment unit outputs a 0~10V analog rate control signal to the variable frequency metering pump to achieve stepless speed regulation of the feeding rate, with a feeding accuracy ≥±1%.

[0038] It also includes a duration control unit, which is the core design for the slow plasticization of polymer plasticizers. When the average real-time temperature T of the material is in the range of 110℃-120℃, the constant temperature plasticization time is accumulated. When the accumulated time reaches the preset value of the process and the feeding is completed, the plasticization completion signal is triggered. When the average real-time temperature T of the material deviates from the range of 110℃-120℃, the accumulation of constant temperature plasticization time is paused until the average real-time temperature T of the material falls back into the range, and then the accumulation of constant temperature plasticization time continues to ensure that the polymer plasticizer is fully plasticized.

[0039] IV. Security Protection Module As a safety assurance module of the system, its core function is to set multi-level temperature thresholds to achieve linkage protection between feeding and cooling / heating. This prevents stabilizer degradation and plasticizer volatilization caused by exceeding the temperature threshold, while also avoiding excessively low temperatures that could affect plasticization. The module communicates with the temperature sensor module and the feeding control module via Ethernet, and is hardwired to the cooling unit of the high-speed mixer to ensure millisecond-level response to cooling / heating intervention commands. It also includes a built-in threshold determination unit and linkage execution unit.

[0040] Specifically, the threshold determination unit is configured to: set three - level temperature thresholds, including a reference plasticizing temperature T0 = 115°C, a first - level warning threshold T1 = 120°C, and a second - level protection threshold T2 = 125°C. The hierarchical speed - regulation strategy of the linkage execution unit is as follows: when T ≤ T1 and T ≥ 110°C, the feeding rate is dynamically adjusted normally according to the plasticizing adaptation coefficient S; when T1 < T < T2, the feeding control module is controlled to reduce the real - time feeding rate V to 0.3V0 - 0.5V0, and at the same time, the cooling temperature of the temperature - control unit of the high - speed mixer is controlled to be 35 - 40°C; when T ≥ T2, the feeding control module is controlled to suspend the feeding of the polymer plasticizer, and the cooling temperature of the temperature - control unit of the high - speed mixer is controlled to be 20 - 30°C; when T < 110°C, the feeding control module is controlled to suspend the feeding, and the temperature - control unit of the high - speed mixer is controlled to heat until T rises to 110°C and then resume the feeding.

[0041] An automatic feeding control method for polymer plasticizers in the preparation of cable sheaths realizes a full - process closed - loop control from temperature monitoring to plasticizing adaptation quantification, to rate dynamic adjustment, to constant - temperature plasticizing guarantee, and finally to safety protection. Specifically, it includes the following steps: S1. When the material temperature of the high - speed mixer rises to 110°C, a feeding start signal is triggered, and the temperature sensor module starts to collect real - time multi - point temperature data of the material. After pre - processing, T, v, and Gt are output and synchronized to the data - processing module and the safety protection module. S2. The data - processing module receives T, v, and Gt, determines whether T is in the 110 - 120°C process interval, calculates the plasticizing adaptation coefficient S according to the corresponding rules, and transmits the plasticizing adaptation coefficient S to the feeding control module in real time. S3. The feeding control module receives the plasticizing adaptation coefficient S, calculates the real - time feeding rate V in combination with the preset reference feeding rate V0, drives the polymer plasticizer feeding device to start feeding at V, and at the same time, the duration control unit starts to accumulate the constant - temperature plasticizing duration at 110 - 120°C. S4. The safety protection module monitors T in real time, determines the temperature state according to the three - level temperature thresholds. If T deviates from the process interval or exceeds the threshold, hierarchical speed - regulation, feeding suspension, and cooling / heating linkage intervention are executed until T returns to the process interval. Then, according to S, the corresponding rate of feeding is resumed and the constant - temperature plasticizing duration is continued to be accumulated. S5. Repeat steps S1 - S4 until the feeding amount of the polymer plasticizer reaches the process - preset value, and the constant - temperature plasticizing duration accumulated by the duration control unit at 110 - 120°C reaches the process - preset value, triggering a feeding - completion signal and stopping the feeding of the polymer plasticizer.

[0042] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An automatic feeding control system for polymer plasticizers in cable sheath preparation, characterized in that, Comprising: A temperature sensor module, which is disposed in the material cavity of the high-speed mixer and is used to collect multi-point temperature data of the material in real time. After preprocessing, it outputs the average real-time temperature T of the material, the heating rate v, and the temperature gradient value Gt. A data processing module, electrically connected to the temperature sensor module, and having a plasticization adaptation coefficient calculation unit therein. The plasticization adaptation coefficient calculation unit calculates the plasticization adaptation coefficient S based on the average real-time temperature T of the material, the heating rate v, and the temperature gradient value Gt. A feeding control module, electrically connected to the data processing module and the polymer plasticizer feeding device respectively, and dynamically adjusts the real-time feeding rate V of the polymer plasticizer feeding device based on the plasticization adaptation coefficient S. When the average real-time temperature T of the material is within the range of 110℃-120℃, the plasticizing compatibility coefficient is... Where T0 is the reference plasticizing temperature in the process range of 110~120℃, k1 is the temperature deviation weighting coefficient, k2 is the temperature rise rate weighting coefficient, and k3 is the temperature gradient weighting coefficient, and k1+k2+k3=1, when the average real-time temperature T of the material deviates from the range of 110℃-120℃... , where λ is the attenuation coefficient.

2. The automatic feeding control system for polymer plasticizers in cable sheath preparation as described in claim 1, characterized in that: The temperature sensor module includes at least five groups of temperature sensors evenly distributed at the front, rear, left, right, and central positions of the material cavity of the high-speed mixer, and has a data preprocessing unit built therein. The data preprocessing unit is configured to: calculate the average value of multi-point temperatures to obtain the average real-time temperature T of the material, calculate the temperature rise rate v through the change amount of T per unit time, and calculate the temperature gradient value Gt through the maximum deviation value between the temperature at each point and T.

3. The automatic feeding control system for polymer plasticizers in cable sheath preparation as described in claim 1, characterized in that, The feeding control module has a rate adjustment unit and a duration control unit built therein. The rate adjustment unit is configured to: preset the reference feeding rate V0 of the polymer plasticizer, and calculate the real-time feeding rate V according to the formula V = V0×S. The duration control unit is configured to: when the average real-time temperature T of the material is within the range of 110°C - 120°C, accumulate the constant temperature plasticization duration. When the accumulated duration reaches the process preset value and the feeding is completed, trigger the plasticization completion signal. When the average real-time temperature T of the material deviates from the range of 110°C - 120°C, pause the accumulation of the constant temperature plasticization duration until the average real-time temperature T of the material falls back within this range and then continue to accumulate the constant temperature plasticization duration.

4. The automatic feeding control system for polymer plasticizers in cable sheath preparation as described in claim 1, characterized in that: It further includes a safety protection module, electrically connected to the temperature sensor module, the feeding control module, and the temperature control unit of the high-speed mixer respectively, and is configured to: set multiple levels of temperature safety thresholds and perform hierarchical speed regulation, feeding pause, and cooling linkage intervention for the polymer plasticizer feeding.

5. The automatic feeding control system for polymer plasticizers in cable sheath preparation as described in claim 4, characterized in that: The safety protection module has a threshold determination unit and a linkage execution unit built therein. The threshold determination unit is configured to: set three levels of temperature thresholds, including the reference plasticization temperature T0 = 115°C, the first-level warning threshold T1 = 120°C, and the second-level protection threshold T2 = 125°C. The hierarchical speed regulation strategy of the linkage execution unit is: when T≤T1 and T≥110°C, normally dynamically adjust the feeding rate according to the plasticization adaptation coefficient S; when T1 < T < T2, control the feeding control module to reduce the real-time feeding rate V to 0.3V0 - 0.5V0, and at the same time control the cooling temperature of the temperature control unit of the high-speed mixer to be 35 - 40°C. When T≥T2, control the feeding control module to pause the polymer plasticizer feeding, and control the cooling temperature of the temperature control unit of the high-speed mixer to be 20 - 30°C; when T < 110°C, control the feeding control module to pause the feeding, and control the temperature control unit of the high-speed mixer to heat until T rises to 110°C and then resume the feeding.

6. The automatic feeding control system for polymer plasticizers in cable sheath preparation as described in claim 1, characterized in that: The polymer plasticizer feeding device is a variable frequency metering pump.

7. An automatic feeding control method for polymer plasticizers in cable sheath preparation, characterized in that: Includes the following steps: S1. When the material temperature in the high-speed mixer rises to 110℃, the feeding start signal is triggered. The temperature sensor module starts to collect multi-point temperature data of the material in real time. After preprocessing, it outputs T, v, and Gt and synchronizes them to the data processing module and the safety protection module. S2. The data processing module receives T, v, and Gt, determines whether T is within the 110~120℃ process range, calculates the plasticizing compatibility coefficient S according to the corresponding rules, and transmits the plasticizing compatibility coefficient S to the feeding control module in real time. When the average real-time temperature T of the material is within the range of 110℃-120℃, the plasticizing compatibility coefficient... Where T0 is the reference plasticizing temperature in the process range of 110~120℃, k1 is the temperature deviation weighting coefficient, k2 is the temperature rise rate weighting coefficient, and k3 is the temperature gradient weighting coefficient, and k1+k2+k3=1, when the average real-time temperature T of the material deviates from the range of 110℃-120℃... , where λ is the attenuation coefficient; S3. The feeding control module receives the plasticizing adaptation coefficient S, calculates the real-time feeding rate V based on the preset benchmark feeding rate V0, and drives the polymer plasticizer feeding device to start feeding according to V. At the same time, the duration control unit starts the accumulation of constant temperature plasticizing time at 110~120℃. S4, the safety protection module monitors T in real time and determines the temperature status according to the three-level temperature threshold. If T deviates from the process range or exceeds the threshold, it will perform graded speed adjustment, pause feeding and cooling / heating linkage intervention until T returns to the process range. Then, according to S, it will resume feeding at the corresponding rate and continue to accumulate the constant temperature plasticizing time. S5. Repeat steps S1-S4 until the amount of polymer plasticizer added reaches the preset process value, and the cumulative constant temperature plasticizing time of 110~120℃ in the time control unit reaches the preset process value, trigger the feeding completion signal, and stop the feeding of polymer plasticizer.

8. The automatic feeding control method for polymer plasticizer in cable sheath preparation as described in claim 7, characterized in that: In step S5, if the constant temperature plasticizing time does not reach the preset process value after the material feeding is completed, the linkage cooling / heating unit of the safety protection module will stabilize T at 110~120℃ until the cumulative time reaches the target.

9. The automatic feeding control method for polymer plasticizer in cable sheath preparation as described in claim 8, characterized in that: The cable sheath comprises, by weight, 37 parts PVC resin, 27 parts dioctyl terephthalate, 10 parts trioctyl trimellitate, 3 parts polymer plasticizer, 3 parts stabilizer, 17 parts nano-activated calcium carbonate, 0.3 parts calcium stearate, 0.3 parts paraffin wax, and 2.4 parts antioxidant. In its preparation, the 37 parts PVC resin, 27 parts dioctyl terephthalate, 3 parts stabilizer, 17 parts nano-activated calcium carbonate, 0.3 parts calcium stearate, and 0.3 parts paraffin wax are first mixed. When heated to 90°C, 10 parts trioctyl trimellitate and 2.4 parts antioxidant are added and mixed. When heated to 110°C, 3 parts polymer plasticizer are added and mixed.

Images