A real-time monitoring method and system for paper cup production

Abstract

The application relates to the technical field of paper cup production and discloses a paper cup production real-time monitoring method and system. The method is characterized in that first and second optical sensors are arranged at a vertical feeding port and a quality inspection position of a vertical conveying line respectively, time stamps and position data in the paper cup conveying process are collected, a continuous time line and a continuous position line are constructed and aligned, time errors and position errors in a preset corresponding interval are calculated, a paper cup conveying abnormality or position abnormality prompt is issued according to a preset threshold value, intelligent discrimination is carried out in combination with visual quality inspection results in an abnormal interval, if the quality inspection results are all qualified, an adsorption abnormality alarm is triggered, otherwise, the paper cup is determined to be abnormal and an alarm is issued. The method can accurately distinguish between adsorption faults and paper cup body defects, effectively avoids visual quality inspection misjudgment, and improves the accuracy and stability of online monitoring of a paper cup production line.

Description

Technical Field

[0001] This application relates to the technical field of paper cup production, and in particular to a method and system for real-time monitoring of paper cup production. Background Technology

[0002] With the continuous improvement of packaging container quality requirements in fields such as food packaging, tea and beverage, high-end gifts, and medical protective equipment, high-quality thick paper cups, with their high structural strength, good heat insulation, and excellent sealing properties, are widely used in high-end applications such as hot beverage serving, cold chain storage and transportation, and disposable hygiene protection. These paper cups have stringent standards for appearance integrity, dimensional accuracy, and molding quality.

[0003] In automated paper cup production lines, the transfer process after paper cup forming often employs negative pressure adsorption to grasp and move materials. Simultaneously, optical sensors are used to count the paper cups on the conveyor line in real time to track production output and monitor material flow. Assuming normal counting and stable conveying, the production line is typically equipped with visual inspection equipment to simultaneously inspect the cups' appearance, dimensional deviations, and forming defects during transfer, enabling online monitoring of the production process and removal of defective products.

[0004] In the case of vertical transfer of paper cups based on spherical fixtures, if the negative pressure adsorption equipment has faults such as air leakage or pressure decay, it is easy to cause unstable adsorption force, which can cause paper cups to shift, tilt or even fall. The paper cups may be in non-standard states such as skewed, flipped or misaligned, which will cause the image information collected by visual inspection to be distorted, resulting in the paper cups being misjudged as unqualified in quality inspection. At the same time, it will also interfere with the subsequent image acquisition and judgment of normal paper cups. Summary of the Invention

[0005] In order to identify factors affecting paper cup quality inspection in advance, this application provides a method and system for real-time monitoring of paper cup production.

[0006] Firstly, this application provides a method for real-time monitoring of paper cup production, employing the following technical solution:

[0007] A method for real-time monitoring of paper cup production includes the following steps:

[0008] A first optical sensor is installed at the vertical feed inlet of the vertical conveyor line. The first optical sensor detects the paper cups being fed and conveyed downward to generate first optical data. The first conveying timestamp and the first conveying position are extracted from the first optical data.

[0009] A second optical sensor is installed on the vertical conveyor line. The second optical sensor detects the paper cups undergoing quality inspection to generate second optical data. The second conveying timestamp and the second conveying position are extracted from the second optical data. The visual quality inspection equipment is located next to the vertical conveyor line and corresponds to the position of the second optical sensor.

[0010] A first continuous timeline is calculated based on the first continuous delivery timestamp, and a second continuous timeline is calculated based on the second continuous delivery timestamp. The paper cups corresponding to the timestamps are aligned with the first and second continuous timelines. The time error between the first and second continuous timelines and the preset corresponding interval is calculated. If the time error is greater than the preset time error, a paper cup delivery abnormality prompt is issued.

[0011] Calculate a first continuous position line based on the first conveying position, calculate a second continuous position line based on the second conveying position, align the paper cups corresponding to the conveying positions with the first and second continuous position lines, calculate the positional error of the first and second continuous position lines within the corresponding interval, and if the positional error is greater than the preset positional error, issue a paper cup position anomaly warning.

[0012] Based on the paper cup conveying abnormality prompts and paper cup position abnormality prompts, the quality inspection results within the corresponding range are extracted. If all the quality inspection results are qualified, an adsorption abnormality alarm is triggered; otherwise, a paper cup abnormality alarm is triggered.

[0013] By adopting the above technical solution, dual optical sensors are deployed on the vertical conveyor line to collect the time and position data of paper cup conveying. The time and position errors in the corresponding intervals are compared and analyzed to identify conveying and position abnormalities. Combined with the quality inspection results, the adsorption equipment failure and the paper cup itself are accurately distinguished and judged. The key factors that interfere with the visual quality inspection of paper cups can be predicted in advance, and the quality inspection misjudgment caused by adsorption abnormalities can be effectively reduced.

[0014] Furthermore, a third optical sensor is positioned between the first and second optical sensors, and the distance between the third optical sensor and the vertical conveyor line is greater than the maximum distance between the paper cup and the vertical conveyor line; the third optical sensor generates an abnormal conveying position after detecting the paper cup;

[0015] Record the generation timestamp of the abnormal delivery location, calculate the backtrack timestamp based on the generation timestamp and the preset backtrack duration, and extract the corresponding quality inspection results based on the backtrack time;

[0016] A material guiding mechanism is installed below the vertical conveyor line; if the quality inspection result is normal, the material guiding mechanism is controlled to guide the paper cup corresponding to the abnormal conveying position into the preset qualified discharge port; otherwise, the material guiding mechanism is controlled to guide the paper cup corresponding to the abnormal conveying position into the preset unqualified discharge port.

[0017] By adopting the above technical solution, a third optical sensor is added to accurately identify offset paper cups that are outside the normal conveying range. Combined with timestamp backtracking to match the corresponding quality inspection results, and the material guiding mechanism is used to intelligently divert the offset paper cups to qualified and unqualified discharge ports. This can effectively reduce quality inspection misjudgments and waste of qualified materials caused by abnormal paper cup positions, and can also realize the sorting and processing of abnormal paper cups.

[0018] Furthermore, the guiding mechanism includes a guide plate suspended at the lower end of the vertical conveyor line, and the guide plate is connected to a telescopic component, which allows the guide plate to be in a first guiding position or a second guiding position.

[0019] The first guide position corresponds to the qualified discharge port, and the second guide position corresponds to the unqualified discharge port.

[0020] By adopting the above technical solution, the guide plate is suspended and combined with telescopic components to achieve flexible switching of the guide position, so that the guide plate can accurately correspond to the qualified and unqualified discharge ports. The overall structure is simple and compact, the action response is fast and the control is stable and reliable, and it can efficiently complete the diversion and guiding operation of paper cups.

[0021] Furthermore, a micro switch is provided on the guide plate, which is used to sense paper cups falling onto the guide plate;

[0022] Once the micro switch is triggered, a trigger timestamp is generated.

[0023] Obtain the recording time period between the trigger timestamps and for a preset recording duration, and extract the paper cup delivery abnormality prompts and paper cup position abnormality prompts within the recording time period; if no paper cup delivery abnormality prompts and paper cup position abnormality prompts are extracted, then a foreign object interference prompt is issued;

[0024] If only abnormal paper cup delivery or abnormal paper cup position is detected, then an abnormal optical sensor warning will be issued.

[0025] By adopting the above technical solution, a micro switch is set on the guide plate to sense the falling paper cup and generate a trigger timestamp. Combined with the abnormal conveying and position prompts within the preset recording time period, the system can intelligently distinguish between foreign object interference and optical sensor malfunctions.

[0026] Furthermore, the method also includes the following steps:

[0027] Based on the generated timestamp and the preset backtracking duration, the time period after the generated timestamp is extracted as the backtracking time period, and the quality inspection results in the backtracking time period are extracted.

[0028] If there are any non-compliant results in the quality inspection, the paper cups corresponding to the non-compliant results will be marked as the affected targets;

[0029] A material-cutting mechanism is installed at the non-conforming discharge port of the vertical conveyor line; when the affected target moves to the non-conforming discharge port, the material-cutting mechanism is controlled to guide the paper cup corresponding to the non-conforming result into the preset re-inspection discharge port.

[0030] By adopting the above technical solution, the unqualified paper cups affected by falling paper cups are located back based on the timestamp and marked as the affected targets. The intercepting mechanism at the unqualified discharge port guides these paper cups into the re-inspection discharge port, reducing the problem of misjudgment in quality inspection caused by the interference of previous paper cups falling.

[0031] Furthermore, the method also includes the following steps:

[0032] The number of times the material is guided by the cutting mechanism within the preset statistical time period is the interception count. If the interception count is greater than the preset number, an alarm will be triggered to indicate an abnormality in the paper cup conveying process.

[0033] By adopting the above technical solution, and by statistically analyzing the number of times the material interception mechanism intercepts within a preset time period and comparing it with a preset threshold, the high-frequency re-inspection interception phenomenon caused by continuous faults such as paper cup jamming can be identified in a timely manner. This enables early warning of potential conveying abnormalities on the production line, facilitating staff to quickly investigate and handle problems such as material jamming.

[0034] Furthermore, the method also includes the following steps:

[0035] If the number of interceptions is less than the set number, the interception feedback value is calculated based on the number of interceptions and the set number.

[0036] The negative pressure power of the control negative pressure device is adjusted according to the interception feedback value. When the interception feedback value increases, the negative pressure power increases; when the interception feedback value decreases, the negative pressure power decreases.

[0037] By adopting the above technical solution, the interception feedback value is calculated based on the number of interceptions, and the negative pressure power of the negative pressure equipment is adaptively adjusted accordingly, forming a closed-loop adjustment mechanism for monitoring and negative pressure control. This can dynamically optimize the paper cup adsorption force and reduce conveying abnormalities such as paper cup deviation and falling from the source.

[0038] Furthermore, the method also includes the following steps:

[0039] When the negative pressure power increases to the preset maximum power value, the rate of change of the interception feedback value is calculated within the subsequent preset temporary duration.

[0040] If the trend of change is greater than the preset comparison trend, a negative pressure failure alarm will be issued and the backup negative pressure module will be activated; otherwise, a negative pressure attenuation alarm will be issued and the backup negative pressure module will be activated.

[0041] The backup negative pressure module is connected in parallel with the current negative pressure module. After the power of the backup negative pressure module is the same as that of the current negative pressure module, the current negative pressure module is turned off.

[0042] The power of the negative pressure module is reduced to the preset operating power according to the preset descent speed.

[0043] By adopting the above technical solution, the change rate of the interception feedback value is monitored when the negative pressure power reaches its maximum value, and the negative pressure failure and attenuation fault are accurately distinguished. The parallel backup negative pressure module is automatically activated and the power is switched synchronously and smoothly. The faulty module is shut down and the negative pressure is adjusted to the standard working power at a preset speed. This enables intelligent identification of negative pressure abnormalities and uninterrupted redundant switching, effectively reducing production line downtime caused by negative pressure failure.

[0044] Furthermore, the method also includes the following steps:

[0045] After replacing the negative pressure module, the power of the negative pressure module was reduced to the operating power.

[0046] If the number of interceptions exceeds the preset reference number, a negative pressure conduction anomaly warning will be issued;

[0047] Where 0 < reference number < set number.

[0048] By adopting the above technical solution, after the negative pressure module is replaced and the power is reduced to the working power, by comparing the number of interceptions with the reference number with a lower threshold, the fault of the negative pressure module itself can be effectively eliminated, and the root cause of the fault can be located as an abnormality in the negative pressure conduction link.

[0049] Secondly, this application provides a real-time monitoring system for paper cup production, which adopts the following technical solution:

[0050] A paper cup production real-time monitoring system includes a processor that performs the steps of the paper cup production real-time monitoring method as described in any of the preceding claims. Attached Figure Description

[0051] Figure 1 This is a flowchart illustrating the steps of a real-time monitoring method for paper cup production.

[0052] Figure 2 This is a flowchart illustrating the steps involved in adding a third optical sensor. Detailed Implementation

[0053] The embodiments of this application are described in detail below, and examples of the embodiments are shown in the accompanying drawings.

[0054] This embodiment discloses a real-time monitoring method for paper cup production, specifically adapted to an automated vertical conveying production line for thick paper cups. This production line is equipped with a negative pressure spherical adsorption transfer fixture, a vertical conveying guide rail, and a visual online quality inspection system. It primarily addresses the technical problems of abnormal paper cup posture, visual inspection distortion, and misjudgment of quality inspection results caused by negative pressure adsorption failures. This method relies on a central monitoring unit composed of a programmable logic controller (PLC) and an industrial control computer to perform logical operations and output instructions, referring to… Figure 1 The specific steps are as follows:

[0055] S1. Data acquisition and reference feature extraction of the first optical sensor

[0056] A first optical sensor is fixedly installed at the end of the vertical feed inlet of the vertical conveyor line. The first optical sensor is preferably a high-speed through-beam photoelectric sensor, with its transmitting end and receiving end symmetrically arranged on both sides of the vertical conveyor line. The detection optical path is perpendicular to the vertical downward conveying direction of the paper cup, and the detection response time is no more than 1ms, so as to ensure that the high-speed conveyed paper cups are detected without omission.

[0057] When a paper cup enters the vertical conveyor line from the feeding station and is conveyed downwards, the paper cup momentarily blocks the optical path of the first optical sensor. The sensor immediately outputs a high-level pulse signal to form the first optical data. The central monitoring unit receives this optical data in real time through the high-speed acquisition module and generates a unique first conveying timestamp for each paper cup with the system clock reference (accuracy of 0.1ms) as a reference. At the same time, combined with the coordinate calibration system of the vertical conveyor line, the initial spatial coordinates of the paper cup at the feeding port are obtained and recorded as the first conveying position. The timestamp and position information of each paper cup are bound and stored to form a paper cup conveying reference data group.

[0058] S2. Data acquisition and quality control feature extraction of the second optical sensor

[0059] A second optical sensor is installed at the position corresponding to the visual quality inspection station on the vertical conveyor line. The second optical sensor also adopts a high-speed through-beam photoelectric sensor. Its installation height and optical path center are aligned and calibrated coaxially with the image acquisition area of ​​the visual quality inspection equipment to ensure that the paper cup detected by the second optical sensor is the same workpiece as the paper cup entering the visual inspection field of view, thus avoiding misalignment of the inspection object.

[0060] When the paper cup is transported to the visual quality inspection area, the second optical sensor is triggered and generates second optical data. The central monitoring unit uses the same clock reference and coordinate system as S1 to extract the second transport timestamp and second transport position of the corresponding paper cup. The timestamp represents the actual time when the paper cup enters the quality inspection station, and the position represents the real-time attitude coordinates of the paper cup in the quality inspection area. The second transport data and the first transport data are uniquely associated through the paper cup time sequence number to ensure that the data of a single paper cup is traceable throughout the entire transport process.

[0061] S3. Continuous Timeline Construction and Paper Cup Conveying Anomaly Detection

[0062] The central monitoring unit uses the first conveying timestamp of N consecutive paper cups as a sample, where N≥5. It can be adaptively set according to the production line speed and arranged in sequence according to the conveying order to construct a first continuous timeline that represents the conveying timeline pattern of the feed inlet. Similarly, it uses the second conveying timestamp of the corresponding paper cup as a sample to construct a second continuous timeline that represents the conveying timeline pattern of the quality inspection station.

[0063] Using the paper cup sequence number as the matching basis, the first and second continuous timelines are aligned point-by-point within a preset corresponding interval. In this embodiment, this is set to a conveying cycle of 10 consecutive paper cups. The absolute difference method is used to calculate the time error between the two timelines at the corresponding matching points. The central monitoring unit has a built-in adjustable preset time error threshold, which is set to ±5ms in this embodiment. If the calculated time error is greater than this threshold, it is determined that the paper cups have experienced conveying abnormalities such as lag, jamming, or speed fluctuations during vertical conveying. The central monitoring unit immediately generates a paper cup conveying abnormality prompt signal, which is synchronously transmitted to the production line HMI for text display and uploaded to the production management system for abnormality recording.

[0064] S4. Construction of continuous position lines and detection of paper cup positional anomalies

[0065] The central monitoring unit performs coordinate fitting along the vertical conveying direction based on the first conveying position coordinates of N consecutive paper cups to form a first continuous position line reflecting the distribution pattern of paper cup positions at the feed inlet; and performs synchronous fitting based on the second conveying position coordinates of the corresponding numbered paper cups to form a second continuous position line reflecting the distribution pattern of paper cup positions at the quality inspection station.

[0066] Using the paper cup's sequence number as the correlation benchmark, the alignment and matching of two consecutive position lines are completed within the preset corresponding interval described in S3. The positional error between the two position lines is calculated using the Euclidean distance algorithm. The monitoring unit presets a positional error threshold, which is set to ±2mm in this embodiment to adapt to the size accuracy requirements of thick paper cups. When the positional error exceeds this threshold range, it is determined that the paper cup has undergone non-standard postures such as lateral displacement, tilting, or flipping during the conveying process. The central monitoring unit then triggers a paper cup position abnormality prompt, which is stored and displayed synchronously with the conveying abnormality prompt.

[0067] S5, Intelligent Anomaly Root Cause Identification and Hierarchical Alarm Control

[0068] Upon receiving a paper cup conveying anomaly alert or a paper cup position anomaly alert, the central monitoring unit immediately locks the preset corresponding range for the anomaly and retrieves all cup appearance, size deviation, and molding defect quality inspection results output by the visual quality inspection equipment within that range.

[0069] If the quality inspection results of all paper cups in this range are deemed qualified, it proves that the quality of the paper cups themselves meets the production standards. The abnormality in conveying and the abnormality in position are not caused by defects in the paper cups, but by equipment failures such as air leakage, pressure decay, and insufficient adsorption force in the negative pressure adsorption equipment. At this time, the central monitoring unit will execute an adsorption abnormality alarm. The alarm forms include audible and visual alarms, HMI interface fault pop-up windows, and mobile terminal information push for maintenance personnel. At the same time, the data of the time period of the fault is locked to facilitate equipment maintenance and source tracing.

[0070] If the visual quality inspection results within this range show any non-compliance, it indicates that the abnormality is caused by quality issues such as molding defects or damage to the appearance of the paper cup itself, and is unrelated to the negative pressure adsorption equipment. The central monitoring unit will issue an abnormal alarm for the paper cup and link the production line rejection mechanism to automatically sort and remove the non-compliant paper cups.

[0071] S6. Abnormal position detection and data correlation of the third optical sensor

[0072] Reference Figure 2 To further detect abnormal offsets of the paper cup during transport between the first and second optical sensors, a third optical sensor is added in the middle section of the vertical transport line between them. This sensor is also a high-speed through-beam photoelectric sensor with a response time of ≤1ms. Its installation method is as follows: the transmitter and receiver are symmetrically arranged on both sides of the vertical transport line, and the horizontal distance between the sensor and the central axis of the vertical transport line is set to 15mm. In this embodiment, the maximum distance between the paper cup and the vertical transport line is 8mm. This setting ensures that the sensor is triggered only when the paper cup experiences severe lateral offset and exceeds the normal transport range, avoiding false triggering by the paper cup in normal posture.

[0073] When a paper cup shifts during transport due to insufficient adsorption or airflow interference, and its edge touches the detection optical path of the third optical sensor, the sensor immediately outputs a trigger signal. After receiving the signal, the central monitoring unit combines it with the current system clock reference to generate the abnormal transport position and the corresponding generation timestamp, and binds and stores the abnormal data with the unique time sequence number of the paper cup.

[0074] The central monitoring unit has a built-in preset backtracking duration, which is adaptively set according to the conveying distance between the first and third optical sensors and the production line conveying speed. In this embodiment, the production line conveying speed is 0.5m / s and the distance between the two sensors is 0.3m, so the preset backtracking duration is set to 0.6s. The backtracking timestamp is calculated using the formula: Backtracking timestamp = Generation timestamp - Preset backtracking duration. Then, based on the backtracking timestamp, the quality inspection results stored by the visual quality inspection equipment before and after the time node are retrieved in a targeted manner to ensure that the backtracking quality inspection results are accurately matched with the paper cups corresponding to the abnormal conveying positions, avoiding data association misalignment.

[0075] S7, Intelligent diversion control of the material guiding mechanism

[0076] A guiding mechanism is fixedly installed at the lower exit of the vertical conveyor line. This mechanism includes a horizontally suspended guiding plate made of food-grade 304 stainless steel with a thickness of 3mm and a width adapted to the diameter of the paper cup. The edges are rounded to avoid scratching the cup. One end of the guiding plate is hinged to the frame of the vertical conveyor line, and the other end is rigidly connected to the telescopic end of the electric telescopic component. The electric telescopic component uses a miniature electric push rod with a stroke of 20mm, an action response time of ≤0.3s, and a load capacity of 5kg. The fixed end of the electric telescopic component is bolted to the frame. The telescopic action of the electric telescopic component drives the guiding plate to rotate around the hinge, realizing the switching between the first guiding position and the second guiding position.

[0077] The first guiding position is the initial default position of the guide plate. At this time, the discharge end of the guide plate is aligned with the preset qualified discharge port, which is located on the lower left side of the guide plate and equipped with a buffer conveyor belt to guide qualified offset paper cups into the qualified material flow. The second guiding position is the position when the electric telescopic component is fully extended. At this time, the guide plate rotates 15° clockwise around the hinge, and the discharge end is aligned with the preset unqualified discharge port, which is located on the lower right side of the guide plate and equipped with a collection hopper to guide unqualified offset paper cups into the waste collection channel.

[0078] After obtaining the backtracked quality inspection results, the central monitoring unit immediately executes the diversion judgment logic: If the quality inspection result is "normal", it means that the quality of the offset paper cup body is qualified, and the third optical sensor was triggered only due to abnormal conveying posture. At this time, the central monitoring unit sends a "maintain initial state" command to the electric telescopic component, and the guide plate maintains the first guide position, smoothly guiding the paper cup into the qualified discharge port, avoiding the qualified material being mistakenly rejected due to abnormal posture; If the quality inspection result is "unqualified", it means that the paper cup itself has quality defects such as appearance damage or size deviation. The central monitoring unit sends a "extend" command to the electric telescopic component, and the telescopic component drives the guide plate to switch to the second guide position, guiding the unqualified paper cup into the unqualified discharge port, realizing the accurate sorting of abnormal paper cups.

[0079] Once the diversion action is completed, the electric telescopic component immediately resets, and the guide plate returns to the first guiding position, awaiting the next abnormal diversion command. The entire diversion process is synchronized with the paper cup conveying rhythm, without affecting the normal operating speed of the production line. At the same time, the central monitoring unit automatically records the paper cup serial number, quality inspection result, diversion time, and destination for each diversion, forming a complete diversion log for easy production traceability and data analysis.

[0080] S7.1 Structural Design and Installation Configuration of the Material Guiding Mechanism

[0081] In this embodiment, the material guiding mechanism serves as a diversion execution component at the end of the vertical conveyor line. Its structural design is fully adapted to the conveying characteristics of paper cups falling vertically and the requirements of high-speed sorting. The specific configuration is as follows:

[0082] (1) Structural parameters and installation method of the guide plate

[0083] The guide plate is made of food-grade 304 stainless steel, integrally molded. This material is corrosion-resistant, has a smooth, burr-free surface, and meets food contact safety standards, preventing scratches and contamination of paper cups during the distribution process. The guide plate's dimensions are precisely matched to the specifications of the thick paper cups used in the production line: the length is set at 120mm, suitable for a general range of paper cup diameters of 50-70mm; the width is 80mm; and the thickness is 3mm, ensuring sufficient structural strength to withstand the impact of the falling paper cups. The upper surface of the guide plate is sandblasted, with a surface roughness Ra=0.8μm, ensuring smooth descent of the paper cups while preventing loss of control due to excessive speed. All edges of the guide plate are rounded with R3mm corners to reduce the risk of sharp edges scratching the paper cups.

[0084] The guide plate adopts a cantilevered installation: its near end, i.e., close to the outlet of the vertical conveyor line, is hinged to the frame beam of the vertical conveyor line by two symmetrically arranged stainless steel hinges with opening angles of 0-90°. The axis of the hinges is parallel to the width direction of the guide plate, ensuring that the guide plate can rotate smoothly around the axis. At the far end of the guide plate, i.e., away from the conveyor line, an L-shaped connecting seat is welded to the bottom, with openings on the connecting seat... The threaded holes are used for rigid connection with the telescopic end of the telescopic component. Elastic washers are added to the connection parts to absorb the impact of the movement and improve structural stability. The installation height of the guide plate is set to 150mm below the vertical conveyor line outlet end to ensure that the vertical drop of the paper cups falling from the conveyor line outlet to the guide plate is moderate, which avoids the paper cups bouncing due to excessive drop and ensures sufficient response time for the diversion action.

[0085] (2) Selection and installation configuration of expansion joints

[0086] The telescopic component uses a miniature electric actuator, which is installed horizontally: its cylinder tail is fixed to the frame with bolts via a U-shaped mounting bracket. The adjustment hole of the mounting bracket is designed with an elongated shape to facilitate fine-tuning of the electric actuator's installation angle. The telescopic end of the electric actuator is threadedly connected to the L-shaped connecting seat at the bottom of the guide plate via a ball joint. The ball joint structure can compensate for force deviations caused by installation errors, preventing jamming during operation. The control signal line of the electric actuator is connected to the digital output module of the central monitoring unit via a shielded cable to achieve stable transmission of command signals. The cable is protected by a corrugated conduit to prevent damage to the wiring caused by production line vibration.

[0087] (3) Calibration and positioning control of the material guide position

[0088] The two guiding positions of the material guiding mechanism are precisely calibrated by the stroke of the electric push rod, and closed-loop control is achieved by a position detection sensor.

[0089] First guiding position (qualified diversion position): When the electric push rod is fully retracted, the guide plate is horizontal. At this time, the far edge of the guide plate is aligned with the inlet end of the preset qualified discharge port, with an alignment deviation of ≤±1mm. The qualified discharge port is equipped with a 100mm wide miniature belt conveyor. The belt surface is covered with a food-grade silicone anti-slip layer to receive and transport qualified offset paper cups to subsequent packaging processes. A magnetic proximity switch is installed below the guide plate corresponding to the first guiding position. When the guide plate is in the first position, the proximity switch is triggered, sending a "qualified position in place" signal to the central monitoring unit to ensure diversion accuracy.

[0090] Second guide position (non-conforming diversion position): When the electric push rod is fully extended, its telescopic end pushes the guide plate to rotate clockwise around the hinge axis. Ultimately, the guide plate forms a 12° tilt angle with the horizontal plane. At this point, the far-end discharge edge of the guide plate aligns with the inlet end of the preset non-conforming discharge port, with an alignment deviation ≤ ±1mm. The non-conforming discharge port is a top-opening collection hopper lined with a sponge cushioning pad to prevent damage to non-conforming paper cups upon falling. A magnetic proximity switch is also installed below the guide plate at the corresponding second guide position to send a "non-conforming position in place" signal to the central monitoring unit, forming a closed-loop position control.

[0091] S7.2 Control Logic and Action Flow for Material Feeding Position Switching

[0092] The position switching of the feeding mechanism strictly follows the instructions of the central monitoring unit, and the action flow is precisely synchronized with the paper cup conveying rhythm, as detailed below:

[0093] 1. Initial state: The material guiding mechanism is in the first material guiding position by default. The electric push rod is fully retracted, the first position proximity switch is triggered, and the central monitoring unit monitors the status signal in real time to ensure that the material guiding plate is in a qualified diversion ready state when in standby.

[0094] 2. Command Reception and Action Execution: When the central monitoring unit determines, based on the abnormal signal from the third optical sensor and the backtracking quality inspection results, that the currently offset paper cup needs to be guided into the unqualified discharge port, it immediately sends an "extend" command to the electric push rod. After receiving the command, the electric push rod extends its telescopic end at a set speed, pushing the guide plate to smoothly rotate from a horizontal position to a 12° tilt position. The entire action process takes 5 seconds, ensuring that the paper cup slides smoothly down the guide plate. When the second position proximity switch is triggered, the electric push rod stops moving and sends a "switching complete" signal back to the central monitoring unit.

[0095] 3. Diversion Completion and Reset: After the offset paper cup has completely slid into the non-conforming discharge port, which can be confirmed by the photoelectric sensor in the hopper, the central monitoring unit sends a "retract" command to the electric push rod after a 0.5s delay to avoid material jamming caused by resetting before the paper cup is completely detached; the telescopic end of the electric push rod retracts in the opposite direction, the guide plate returns to the horizontal first guide position, the first position proximity switch is triggered again, and one diversion action cycle is completed;

[0096] 4. Abnormal protection mechanism: If the electric push rod does not receive a position feedback signal within the preset time (10s) during the operation, the central monitoring unit determines that the operation is stuck, immediately issues a "material guiding mechanism failure" alarm, and suspends the production line conveying to avoid batch paper cup accumulation or incorrect diversion.

[0097] S7.3 Microswitch Selection, Installation, and Triggering Mechanism

[0098] To detect paper cups falling onto the guide plate (including paper cups with abnormal postures and foreign objects) and to trace the source of faults, a microswitch is added to the guide plate as a trigger detection element. Its selection, installation, and triggering logic are all adapted to the operating characteristics of the production line. The specific configuration is as follows:

[0099] (1) Selection parameters of micro switches

[0100] Waterproof and dustproof microswitches are selected to ensure stable signal transmission and avoid false triggering caused by poor contact. The switch is equipped with a long-handled roller-type trigger head, which is triggered by the rolling contact between the roller and the paper cup, reducing interference with the paper cup's posture and minimizing wear on the switch itself.

[0101] (2) Installation location and fixing method

[0102] The micro switch is fixed to the lower surface of the guide plate via an L-shaped stainless steel mounting bracket. The installation position meets two requirements: ① It is located at the midpoint of the guide plate's length, 60mm from the near-end hinge and 60mm from the far-end edge, ensuring that the switch is triggered regardless of whether the paper cup falls onto the front, middle, or rear of the guide plate; ② The switch trigger head faces upwards and penetrates the guide plate. The mounting hole has the top of the roller protruding 1.5mm above the top surface of the guide plate. This ensures that the roller can be effectively pressed to trigger the switch when the paper cup falls, while also preventing the roller from protruding too high and affecting the normal descent of the paper cup.

[0103] The mounting bracket is secured to the lower surface of the guide plate with M3 stainless steel countersunk screws, and anti-loosening washers are added at the screw connections to prevent loosening caused by production line vibration. The micro switch is secured to the bracket with a snap-fit ​​mechanism for easy disassembly and maintenance. The switch lead wire uses shielded cable with a corrugated conduit for protection, and is routed along the lower surface of the guide plate to the rack junction box, ultimately connecting to the digital input module of the central monitoring unit to ensure that the trigger signal is not subject to electromagnetic interference.

[0104] (3) Triggering logic and timestamp generation

[0105] When a paper cup falls from the vertical conveyor line onto the guide plate due to adsorption failure, severe posture abnormalities, or other reasons, or when foreign objects (such as paper scraps or small parts) fall, the weight of the object (≥5g, the minimum weight of the compatible paper cup) presses against the roller of the micro switch, causing the switch contact to switch from a normally closed state to a normally open state, generating a high-level trigger signal. The central monitoring unit collects this trigger signal in real time, uses the system's unified clock reference as a reference, generates a unique corresponding trigger timestamp, and stores it in association with the current working state of the guiding mechanism (first / second guiding position) and the paper cup's sequence number, forming a complete data chain for the trigger event.

[0106] If an object continues to press on the switch, such as a paper cup stuck on the guide plate, the switch will remain in the triggered state. The central monitoring unit will only record the timestamp of the first trigger to avoid generating duplicate data. When the object leaves the guide plate, such as sliding into the discharge port or being manually cleaned, the switch contacts will reset. The central monitoring unit will record the reset time as the end point of the trigger event.

[0107] S7.4 Abnormal Linkage Comparison Logic and Prompt Control

[0108] After generating the trigger timestamp, the central monitoring unit immediately initiates the linkage comparison and analysis process. By retrieving historical anomaly alert data, it intelligently distinguishes between foreign object interference and optical sensor malfunctions. The specific process is as follows:

[0109] (1) Delineation of recording time periods

[0110] The central monitoring unit has a built-in preset recording duration, which is set based on the production line conveyor speed and the detection cycle of the optical sensor. In this embodiment, it is set to 8 seconds to cover any abnormal prompts that may occur before and after the trigger event. Based on the trigger timestamp, a continuous time period from "trigger timestamp - 3 seconds" to "trigger timestamp + 5 seconds" is defined as the recording time period. Going back 3 seconds is to cover any abnormal prompts that may have occurred before the trigger but were not responded to in time, and extending forward 5 seconds is to capture subsequent abnormalities caused by object interference after the trigger, ensuring that no abnormal data is missed.

[0111] (2) Extraction and comparison of abnormal prompt data

[0112] The central monitoring unit extracts two types of key data from the historical database within the recorded time period: ① Paper cup delivery anomaly alerts (generated in step S3); ② Paper cup position anomaly alerts (generated in step S4). After extraction, the data is compared and judged according to the following logic:

[0113] Scenario 1: No abnormality indication → Foreign object interference indication

[0114] If no abnormal paper cup conveying or paper cup position indications are retrieved within the recorded time period, it indicates that the paper cup conveying timing and spatial posture of the vertical conveyor line are normal. The microswitch triggering is not caused by a paper cup falling, but by a foreign object (such as paper scraps, dust clumps, small tool parts, etc. from the production environment) falling. In this case, the central monitoring unit immediately issues a foreign object interference warning:

[0115] A red prompt box pops up on the HMI (Human Machine Interface), displaying "Foreign Object Interference on the Guide Plate," and simultaneously indicating the trigger timestamp and the current position of the guide plate.

[0116] The audible and visual alarm on the production line emits an intermittent yellow alarm (once per second) to remind staff to clean up in time;

[0117] Trigger event data (trigger time, recording time period, no abnormality prompt indicator, prompt type) is automatically stored in the production log for easy traceability later;

[0118] The production line will not be stopped (the foreign object did not affect the paper cup conveying), but will continue to display a warning until staff confirm the cleanup and reset.

[0119] Scenario 2: Single anomaly alert → Optical sensor anomaly alert

[0120] If only one paper cup conveying abnormality alert or one paper cup position abnormality alert is extracted within the recording time period, and the two do not exist simultaneously, it indicates a logical contradiction in the abnormality alert data. Normally, paper cup conveying abnormalities and position abnormalities often occur together, such as insufficient suction causing conveying lag and simultaneously triggering attitude deviation, or neither may occur. The appearance of a single abnormality alert most likely indicates a malfunction in the first / second optical sensor, such as light path obstruction, signal transmission interruption, or detection accuracy drift, leading to data acquisition distortion. In this case, the central monitoring unit will issue an optical sensor abnormality alert:

[0121] A red alarm window pops up on the HMI (Human Machine Interface), displaying "Optical sensor malfunction," clearly indicating "only conveyor malfunction detected" or "only position malfunction detected," and listing the possible faulty sensors (first / second optical sensors).

[0122] The audible and visual alarm emits a continuous red alarm and simultaneously pushes a fault notification to the mobile device of the maintenance personnel.

[0123] Automatically lock relevant data for the fault period, including raw optical data collected by the sensor, abnormal prompts generated logs, and trigger timestamps, to facilitate fault diagnosis;

[0124] The production line was kept running at a low load, with the conveyor speed reduced to 50% of the normal speed to prevent the fault from escalating until maintenance personnel inspected the sensor and confirmed that it had been reset.

[0125] (3) Prompt for reset and status recovery

[0126] After the staff has finished cleaning up foreign objects or repairing sensors, they can click the "Abnormal Confirmation" button on the HMI interface. The central monitoring unit will receive a reset signal, stop the audible and visual alarms, clear the interface prompts, and the production line will resume normal operation. All abnormal handling records (handling personnel, handling time, handling method, recovery status) are simultaneously stored in the production management system, forming a complete fault handling closed loop.

[0127] S8. Interference Affects Target Localization and Retrospective Quality Inspection Analysis

[0128] When the third optical sensor detects a paper cup offset and generates an abnormal conveying position and corresponding timestamp, or when a micro switch triggers a trigger timestamp, the central monitoring unit immediately initiates the interference impact tracing process to accurately locate the abnormal paper cup affected by the previous paper cup drop / off. The specific implementation is as follows:

[0129] (1) Precise definition of the retrospective time period

[0130] The central monitoring unit has a built-in preset backtracking time, which is dynamically set based on the actual conveying parameters of the production line. The calculation logic is: backtracking time = (horizontal distance between the installation position of the third optical sensor / micro switch and the detection area of ​​the visual quality inspection equipment ÷ production line conveying speed) + single detection cycle of the visual quality inspection equipment + redundant buffer time. In this embodiment, the above distance is 0.4m, the production line conveying speed is 0.5m / s, the detection cycle is 0.2s, and the redundant buffer time is 0.3s. Therefore, the preset backtracking time is set to 1.3s.

[0131] Starting from the generated timestamp, a continuous time period of "generated timestamp + preset backtracking duration" is extracted as the backtracking time period. The basis for this setting is that after the preceding paper cup falls / shifts, its interference to the subsequent paper cups, such as airflow disturbance and posture collision, will continue until a certain number of subsequent paper cups are inspected. The backtracking time period must fully cover this interference cycle to ensure that no affected quality inspection data is missed.

[0132] (2) Extraction of quality inspection results and impact on target marking

[0133] The central monitoring unit uses a timestamp association mechanism to selectively extract all quality inspection results output by the visual quality inspection equipment within the retrospective time period, including sub-item inspection data and comprehensive judgment results such as cup appearance damage, dimensional deviation, and molding defects. The system has a built-in quality inspection result filtering logic: it compares the comprehensive judgment result of each paper cup within the retrospective time period one by one. If there is at least one "non-conforming" judgment, regardless of the type of individual defect, the paper cup is marked as an affected target.

[0134] The marking of the affected targets adopts a dual binding method of "time sequence number + interference identifier": each paper cup is assigned a unique global time sequence number when it enters the vertical conveyor line, which starts from 1 and increments, and is stored in the central monitoring unit database. When marking, the interference identifier, such as 'OFFSET-XXX', where XXX is the last 6 digits of the generated timestamp, is bound to the time sequence number. At the same time, it is associated with the timestamp, location data, and sub-item quality inspection data collected by its first / second optical sensors during the retrospective time period, forming a complete data file of the affected targets to ensure that subsequent traceability is possible.

[0135] If all quality inspection results within the retrospective time period are "qualified", then it is determined that there are no unqualified paper cups affected by interference, no target marker is generated, and the system maintains the normal diversion process.

[0136] S9. Structural Design and Interception Control of the Cutting Mechanism

[0137] To achieve precise diversion and re-inspection of the affected targets, a material interception mechanism is added 50mm in front of the non-conforming material outlet of the vertical conveyor line. This mechanism acts as a pre-interception execution component of the non-conforming material outlet and works in conjunction with the central monitoring unit to achieve directional introduction of the affected targets. The specific configuration is as follows:

[0138] (1) Selection and installation of material cutting mechanism

[0139] The material cutting mechanism uses a food-grade electromagnetic drive flap assembly, the structure of which includes:

[0140] The main body of the flip plate is made of food-grade 304 stainless steel, with a thickness of 2mm and a length of 80mm. It is suitable for paper cups with a diameter of 50-70mm and a width of 30mm. The edges are rounded with R2mm to avoid scratching the paper cups. One side of the flip plate is hinged to the frame through a miniature bearing, and it can be rotated from 0 to 90° around the hinge axis. The rotation stroke is a switch between "vertical interception posture" and "horizontal release posture".

[0141] Drive component: A miniature electromagnetic push rod is used. Its cylinder is fixed to the frame with bolts through an L-shaped bracket. The telescopic end is hinged to the bottom of the flap through a connecting rod. The movement of the electromagnetic push rod directly drives the flap to flip. The drive component is equipped with a return spring to ensure that the flap automatically returns to the horizontal release posture when the power is off, thus improving safety.

[0142] Position detection: Magnetic proximity switches are installed on both sides of the flap, corresponding to the "interception posture" and "release posture" respectively. These switches are used to feed back the real-time position of the flap to the central monitoring unit, forming a closed-loop control and avoiding interception failure due to incomplete action.

[0143] The installation height of the cutting mechanism is set at 80mm, and the vertical distance between it and the outlet of the vertical conveyor line is set to ensure that the paper cups are stable when they fall into the cutting area. The hinge shaft of the flip plate is parallel to the central axis of the vertical conveyor line, and the flipping direction is towards the re-inspection outlet side, so that the paper cups can slide smoothly into the re-inspection outlet when intercepted.

[0144] (2) Re-inspection of the configuration of the discharge port

[0145] The re-inspection outlet is located on the lower side of the cutting mechanism, at a 60° angle to the non-conforming outlet, to avoid conflict with the diversion path of normal non-conforming paper cups.

[0146] The main body of the re-inspection outlet is a transparent PP plastic collection box. The top opening of the box is 100mm×100mm, and the inside is lined with a 2mm thick food-grade silicone cushioning pad to reduce impact damage when the target falls.

[0147] A "Re-inspection Only" label is affixed to the outside of the container, and a small photoelectric sensor is installed to detect the amount of material accumulated inside. When the material reaches 80% of the container's volume, a "Re-inspection Container Full" notification is sent to the central monitoring unit to remind staff to handle the situation promptly.

[0148] (3) Interception control logic and action flow

[0149] The interception mechanism strictly follows a closed-loop process of "target location impact - position detection - precise interception - reset and release," as detailed below:

[0150] 1. Pre-preparation state: The cutting mechanism is in the "horizontal release posture" by default. The flap is parallel to the paper cup conveying path. Normal unqualified paper cups can slide directly into the unqualified discharge port. The central monitoring unit receives the "release posture" feedback signal from the flap position sensor in real time. At the same time, the positioning photoelectric sensor at the end of the vertical conveyor line (installed 20mm behind the cutting mechanism) monitors the conveying position of the paper cups in real time.

[0151] 2. Impact Target Positioning and Triggering: After the central monitoring unit marks the impact target, it associates its second conveying timestamp with the global time sequence number and calculates the estimated time for the impact target to reach the cutting mechanism by combining the production line conveying speed. Estimated arrival time = second conveying timestamp + (distance between the second optical sensor and the cutting mechanism ÷ conveying speed); when the positioning photoelectric sensor detects the impact target (by matching the time sequence number), it immediately sends a "target arrived" signal to the central monitoring unit.

[0152] 3. Interception Action Execution: After receiving the "target arrives" signal, the central monitoring unit delays for 0.05 seconds to compensate for the slight time difference in paper cup delivery before sending an "interception" command to the material cutting mechanism. The electromagnetic push rod is energized, driving the flap to quickly rotate from a horizontal position to a vertical interception position. At this time, the flap vertically blocks the normal falling path of the paper cup and guides the paper cup to deviate towards the re-inspection discharge port. When the "interception position" proximity switch on the flap side is triggered, the central monitoring unit confirms that the interception is in place.

[0153] 4. Reset and Release: Once the affected target has completely slid into the re-inspection outlet, it is confirmed by the photoelectric sensor at the re-inspection outlet. The central monitoring unit sends a "power-off reset" command to the electromagnetic push rod after a delay of 0.1s. The electromagnetic push rod is de-energized, and the flap is reset to the horizontal release posture under the action of the return spring. The "release posture" proximity switch is triggered, completing one interception cycle. Subsequent normal but unqualified paper cups continue to be diverted through the unqualified outlet.

[0154] (4) Anomaly protection mechanism

[0155] If the material interception mechanism does not receive a "interception posture" feedback signal within 0.3 seconds after receiving the "intercept" command, the central monitoring unit determines that the action is stuck and immediately issues an "interception mechanism failure" alarm, such as an audible and visual alarm + HMI pop-up window, and suspends the production line conveying to avoid affecting the target from being mixed with unqualified materials or normal material flow.

[0156] If the target material is not successfully guided to the re-inspection outlet by the material cutting mechanism, the positioning photoelectric sensor detects that the target has passed through the material cutting area, but the sensor at the re-inspection outlet does not detect the material. The system records this anomaly, marks the corresponding time sequence number, and reminds the staff to check manually.

[0157] S10. Interception Count Statistics and Transmission Anomaly Early Warning Control

[0158] To promptly identify high-frequency re-inspection and interception phenomena caused by persistent faults in the production line, such as paper cup jamming, negative pressure adsorption failure, and conveyor guide deformation, this application achieves early warning of conveying anomalies by periodically statistically analyzing the number of interceptions by the material cutting mechanism and comparing it with a threshold. The specific implementation is as follows:

[0159] (1) Precise setting of statistical parameters

[0160] The central monitoring unit has two built-in statistical parameters. The parameter values ​​can be dynamically calibrated according to production line capacity and equipment operation and maintenance standards. The specific setting logic is as follows:

[0161] Preset statistical duration: This is set based on the production line's fault response cycle and normal fluctuation range. The principle is to cover the outbreak cycle of persistent faults while avoiding false alarms caused by an excessively short statistical period. In this embodiment, the normal production speed of the production line is 60 units / minute, and the cycle from the initial occurrence of a single fault to triggering a batch anomaly is approximately 10 minutes. Therefore, the preset statistical duration is set to 5 minutes (300 seconds), which can be adjusted from 0 to 30 minutes through the parameter configuration module of the HMI interface.

[0162] Preset number of attempts: Determined based on historical operation and maintenance data and qualified quality control standards, this is the upper limit of the number of times the target affected by interference can be intercepted within 5 minutes under normal production conditions. This embodiment, through statistical analysis of 100 sets of normal production data, found an average of 3 interceptions within 5 minutes. Therefore, the preset number of attempts is set to 10, reserving a 2x redundancy to avoid false triggering due to normal fluctuations. It supports adjustable calibration from 1 to 50 times, adapting to the production needs of different paper cup sizes.

[0163] (2) Statistical logic of the number of interceptions

[0164] The central monitoring unit has established an independent interception count statistics module. The statistical logic strictly follows the principle of valid interception counting to avoid invalid actions interfering with the accuracy of the statistics.

[0165] Counting trigger conditions: The counting module will only increment the interception count by 1 after the material cutting mechanism completes a complete and valid cycle of receiving the interception command → flipping to the interception posture → affecting the target to slide into the re-inspection discharge port → resetting to the release posture, and the photoelectric sensor of the re-inspection discharge port confirms that the material has been received. If an abnormality such as action stagnation or failure to import the target occurs during the interception process, and the material cutting mechanism fault alarm has been triggered, this action will not be counted as a valid interception.

[0166] Statistical period management: The statistical module starts periodic timing based on a preset statistical duration. The start time of each statistical period is the end time of the previous period + 1 second, ensuring that there is no overlap or omission of periods. After each period ends, the statistical module automatically stores the number of interceptions, the corresponding time range, and the time sequence number of the associated affected targets within that period, forming an interception statistical log for easy traceability and analysis later.

[0167] Real-time update mechanism: The number of interceptions is synchronized in real time to the device status monitoring section of the HMI human-machine interface, and displayed in the form of numbers and progress bars. When the progress bar is full, it corresponds to the preset number of times. Staff can intuitively grasp the interception trend within the current statistical period.

[0168] (3) Alarm triggering conditions and notification mechanism

[0169] When the current statistical period ends, the central monitoring unit automatically compares the number of valid interceptions within that period with the preset number, triggering the corresponding early warning logic:

[0170] If the number of interceptions exceeds the preset number, such as ≥11 times in this embodiment, the production line is determined to have a continuous conveying abnormality. Possible fault points include: paper cups stuck in the detection area of ​​the visual quality inspection equipment, continuous air leakage of the negative pressure adsorption equipment, frequent abnormal paper cup posture caused by the deviation of the conveying guide rail, and excessive deviation of the material's own size. The central monitoring unit will immediately activate the paper cup conveying abnormality alarm prompt.

[0171] The alarm notification system employs a multi-level linkage mechanism to ensure rapid response from staff.

[0172] 1. On-site audible and visual alarm: The red audible and visual alarm on the production line control cabinet is activated, emitting a continuous alarm sound (volume ≥ 85dB) and the alarm light flashes (frequency 2 times / second).

[0173] 2. HMI Interface Prompt: A full-screen red alarm pop-up window appears, displaying the message: Paper cup conveying abnormality! Statistical period: XX:XX-XX:XX, Number of interceptions: X times, Set number of times: 10 times. Possible troubleshooting directions are listed simultaneously, such as: 1. Check if there is material jamming in the visual inspection area; 2. Verify the pressure value of the negative pressure adsorption equipment; 3. Check the parallelism of the conveyor rails.

[0174] 3. Remote notification push: Send alarm information to the mobile APP of designated maintenance personnel through the production management system, including alarm time, production line number, details of the number of interceptions, and support one-click reply with "received" or "processing" status;

[0175] 4. Production line status lock: After the alarm is triggered, the production line will automatically reduce the conveying speed to 30% of the normal speed to avoid the fault from escalating and causing batch abnormalities, but will not stop the machine directly, allowing time for troubleshooting; if the alarm is not handled within 15 minutes, the production line will automatically stop and lock to prevent the accumulation of defective products.

[0176] (4) Alarm reset and statistical reset

[0177] After staff have identified and resolved the fault, such as clearing stuck paper cups, repairing negative pressure equipment, or calibrating the conveyor rails, they can click the "Alarm Reset" button on the HMI interface. Upon receiving the reset signal, the central monitoring unit will then...

[0178] 1. Stop the audible and visual alarms and remote notifications, and turn off the HMI alarm pop-up window;

[0179] 2. Store the number of interceptions and fault handling information (handling personnel, handling time, fault cause) for the current statistical period in the production log;

[0180] 3. Reset the interception count statistics module, start a new statistics cycle, and the production line resumes normal conveying speed.

[0181] S11. Interception Feedback Value Calculation and Negative Pressure Power Adaptive Adjustment

[0182] When the number of interceptions within the preset statistical period is less than the preset number, it indicates that there is a slight, intermittent conveying abnormality in the production line, such as slightly insufficient negative pressure adsorption force or minor disturbances in the ambient airflow. No shutdown is required for troubleshooting. The adsorption effect can be optimized from the source by dynamically adjusting the power of the negative pressure equipment. The specific implementation is as follows:

[0183] (1) Quantitative calculation logic for intercepted feedback values

[0184] The central monitoring unit has a built-in feedback value calculation module that quantifies the severity of transmission anomalies based on the "relative ratio of the number of interceptions to the set number of interceptions." The calculation method uses a linear proportional algorithm to ensure that the feedback value accurately matches the actual anomaly situation. The specific formula is as follows:

[0185] Interception feedback value K = Actual number of interceptions N ÷ Preset number of interceptions N0; where:

[0186] The actual number of interceptions N is the number of valid interceptions within the current statistical period, following the valid counting principle in S10, and its value range is 0≤N<N0;

[0187] The preset number of times N0 is the threshold set in S10. In this embodiment, N0 = 10 times.

[0188] The range of the interception feedback value K is 0≤K<1. The closer K is to 1, the closer the transmission abnormality is to the critical state, and the negative pressure power needs to be increased. The closer K is to 0, the more stable the transmission state is, and the negative pressure power can be maintained or reduced to save energy.

[0189] After the calculation is completed, the interception feedback value K is synchronized to the HMI interface in real time and displayed in the form of a numerical value and a trend curve. The horizontal axis of the trend curve represents the statistical period number, and the vertical axis represents the K value, which makes it easy for staff to intuitively observe the abnormal change trend. At the same time, the feedback value is bound and stored with the number of interceptions and the negative pressure power value of the corresponding statistical period, forming an adjustment and traceability data chain.

[0190] (2) Controllable configuration and adjustment range of negative pressure equipment

[0191] In this embodiment, a variable frequency oil-free vacuum pump is selected as the negative pressure device, and its adaptability characteristics are as follows:

[0192] Equipped with a vector frequency converter, it supports receiving power adjustment commands from the central monitoring unit via 4-20mA analog signals or RS485 communication, with an adjustment accuracy of ±1% of the rated power;

[0193] A high-precision negative pressure sensor is installed at the output end of the vacuum pump to collect the actual negative pressure value in real time and feed it back to the central monitoring unit, forming a closed-loop feedback for power regulation.

[0194] A pressure regulating valve is installed on the gas pipeline of the negative pressure adsorption fixture. In conjunction with the power adjustment of the vacuum pump, the adsorption force can be precisely controlled to avoid sudden power changes that could cause the paper cup to deform.

[0195] The central monitoring unit presets the adjustment boundary for negative pressure power:

[0196] Minimum adjustable power: 50% of the rated power (0.75kW), corresponding to a negative pressure of approximately -0.04MPa, ensuring that the basic adsorption requirements of paper cups are met even at the lowest power, preventing them from falling off;

[0197] Maximum adjustable power: 90% of the rated power (1.35kW), corresponding to a negative pressure of approximately -0.07MPa, which is lower than the critical pressure for paper cup deformation, preventing excessive adsorption that could cause the cup to dent.

[0198] (3) Dynamic adjustment logic and execution process of negative pressure power

[0199] Based on the interception feedback value K, the central monitoring unit outputs a power adjustment command according to the principles of linear correspondence and stable adjustment. The specific adjustment logic is as follows:

[0200] 1. Reference power calibration: The system defaults to a reference power of 70% of the rated power (1.05kW), corresponding to a negative pressure of -0.05MPa, which is suitable for the regular adsorption needs of most thick paper cups; the reference power can be calibrated by 0.6-0.8 times the rated power according to the paper cup specifications (such as diameter and wall thickness) through the HMI parameter configuration module.

[0201] 2. Adjustment coefficient setting: Set the power adjustment coefficient α=0.4 (can be dynamically calibrated), that is, for every 0.1 change in the feedback value K, the corresponding power change is 4% of the rated power, to ensure a smooth adjustment range and avoid sudden changes in adsorption force.

[0202] 3. Target power calculation: Target power P_target = Base power P_base + (K - 0.3) × α × Rated power P_rated;

[0203] When K > 0.3, (K - 0.3) is a positive value, the target power is higher than the reference power, and the negative pressure is increased;

[0204] When K < 0.3, (K - 0.3) is negative, the target power is lower than the reference power, and the negative voltage is reduced.

[0205] When K=0.3, the target power equals the reference power, and the current state is maintained.

[0206] Example: In this embodiment, P_rated=1.5kW, P_base=1.05kW, α=0.4; if K=0.6, and the number of interceptions is 6, then P_target=1.05+(0.6-0.3)×0.4×1.5=1.05+0.18=1.23kW, which is 82% of the rated power.

[0207] 4. Adjustment execution and closed-loop verification:

[0208] The central monitoring unit sends the target power command to the frequency converter via RS485 communication. After receiving the command, the frequency converter drives the vacuum pump to smoothly adjust the speed. The speed change rate during the adjustment process is set to 5% / s to avoid sudden power changes.

[0209] The negative pressure sensor collects the actual negative pressure value in real time and feeds it back to the central monitoring unit. If the deviation between the actual negative pressure value and the theoretical negative pressure value corresponding to the target power exceeds ±0.005MPa, the system automatically adjusts the power command. The adjustment range is ≤2% of the rated power until the deviation meets the requirements.

[0210] After each adjustment is completed, the system records the adjustment time, power before adjustment, target power, actual negative pressure value, and interception feedback value, forming a complete adjustment log.

[0211] (4) Adjustment stability assurance and adaptation optimization

[0212] Synchronization of adjustment cycle: The negative pressure power adjustment is synchronized with the interception count statistics cycle, that is, only one adjustment is performed after each statistics cycle ends, to avoid frequent adjustments that may cause system oscillation;

[0213] Adjustment step size limit: The power change in a single adjustment shall not exceed 10% of the rated power. Even if the K value changes abruptly, such as from 0.1 to 0.9, it shall be gradually approached to the target power in multiple cycles to ensure a smooth transition of adsorption force.

[0214] Specification adaptation calibration: For paper cups with different diameters (50-70mm) and wall thicknesses (0.3-0.8mm), the power adjustment coefficient α and the reference power P_base can be preset in the HMI interface to form an adaptation parameter group. When switching paper cup specifications, the corresponding parameters are automatically called to improve the adjustment targeting.

[0215] Low-load energy saving: When the interception feedback value K=0 for three consecutive statistical cycles, there is no effective interception. The system will automatically reduce the negative pressure power to the minimum regulation power (0.75kW) and continuously monitor it. If K>0 occurs in the future, the system will start the regulation according to the above logic to achieve a balance between energy saving and stability.

[0216] S12. Negative Pressure Power Critical State Monitoring and Fault Diagnosis

[0217] When the negative pressure power reaches the preset maximum power value through the adaptive adjustment of S11, which in this embodiment is 90% of the rated power, i.e., 1.35kW, corresponding to a negative pressure value of -0.07MPa, it indicates that the main negative pressure module is currently operating at full load. If it still cannot effectively suppress the abnormal transmission, it is necessary to further determine the fault type (negative pressure failure / negative pressure attenuation) and initiate redundancy switching. The specific implementation is as follows:

[0218] (1) Presetting and calibration of monitoring parameters

[0219] The central monitoring unit has built-in critical state monitoring parameters. The parameter values ​​are based on the performance parameters of the main negative pressure module and the production line fault tolerance standards, ensuring accurate fault diagnosis.

[0220] Preset maximum power value P_max: The upper limit of negative pressure power adjustment set in S11 is 1.35kW, which is 90% of the rated power of 1.5kW. This value is locked by the inverter parameters to avoid over-power operation that could damage the equipment.

[0221] Preset temporary duration T_temp: Set to 2 complete interception count statistics periods. In this embodiment, a single statistics period is 5 minutes, so T_temp=10 minutes, to ensure sufficient time to observe the changing trend of the interception feedback value and avoid misjudgment caused by short-term fluctuations;

[0222] Preset comparison trend K_ref: Quantifies the change slope of the intercepted feedback value per unit time, set to -0.02 / minute (the negative sign indicates that the decrease of the feedback value is a normal trend, that is, if the decrease rate of the feedback value is faster than the slope and the absolute value is larger, it is judged as an effective improvement; if the decrease rate is slower than the slope or increases, it is judged as a fault state.

[0223] (2) Calculation logic for the rate of change of intercepted feedback value

[0224] Once the negative pressure power reaches P_max, the central monitoring unit immediately starts a temporary duration timer and synchronously records the interception feedback values ​​K1, K2, ..., Kn for each statistical cycle within the temporary duration, where n = T_temp ÷ statistical cycle duration. In this embodiment, n = 2, meaning K1 is the feedback value for the first statistical cycle and K2 is the feedback value for the second statistical cycle.

[0225] The rate of change v is calculated using a linear regression slope algorithm, as shown in the following formula:

[0226] v=(n×Σ(i×K_i)-Σi×ΣK_i) / (n×Σi 2 -(Σi) 2 );

[0227] Where: i is the statistical period number (1≤i≤n); K_i is the interception feedback value of the i-th statistical period; the unit of v is "feedback value / minute", a negative v value indicates that the interception feedback value decreases and the transmission anomaly improves, a positive v value indicates that the feedback value increases and the transmission anomaly worsens, and the larger the absolute value of v, the faster the rate of change.

[0228] After the calculation is completed, the system compares the rate of change v with the preset comparison trend K_ref to determine the fault type:

[0229] If v > K_ref, meaning the change trend is slower than the preset improvement rate, such as v = -0.01 / minute > -0.02 / minute, or v = 0.005 / minute > -0.02 / minute, it indicates that even if the main negative pressure module is running at full load, the abnormal delivery has not been effectively improved or has even worsened. This is determined to be a negative pressure failure. The possible causes of the failure are: serious leakage in the main negative pressure module's air circuit, wear of the vacuum pump rotor, damage to the suction cup of the adsorption tool, etc.

[0230] If v ≤ K_ref, meaning the change trend is faster than or equal to the preset improvement rate, such as v = -0.03 / minute ≤ -0.02 / minute, it indicates that after the main negative pressure module is running at full load, the abnormality in the delivery has been improved but not completely eliminated. This is determined to be negative pressure attenuation. The possible causes of the fault are: blockage of the filter screen of the main negative pressure module, slight leakage in the pipeline, and decreased efficiency of the vacuum pump.

[0231] S13. Configuration and Redundancy Switching Procedure for Backup Negative Pressure Module

[0232] To achieve seamless switching in case of negative pressure failure, the system is configured with a backup negative pressure module that is identical to the main negative pressure module. It employs a main / backup parallel connection and gas path interlocking design. The specific switching procedure is as follows:

[0233] (1) Pre-installation and linkage configuration of backup modules

[0234] Hardware configuration: The backup negative pressure module and the main negative pressure module are connected in parallel to the same adsorption gas path main pipe. Electromagnetic shut-off valves are installed at the outlet of both the main and backup modules. Two high-precision negative pressure sensors are installed on the gas path main pipe to monitor the output pressure of the main and backup modules respectively, ensuring pressure synchronization accuracy.

[0235] Control linkage: The inverter and solenoid shut-off valve of the standby module communicate with the central monitoring unit via RS485 bus to achieve command synchronization and status feedback; the central monitoring unit has a built-in main and standby module status monitoring module to collect the operating parameters (power, speed, negative pressure value) of the main and standby modules in real time, ensuring that the standby module is in standby ready state before switching, and that the power is cut off, the shut-off valve is closed, and the inverter parameters are consistent with those of the main module.

[0236] (2) Fault alarm and backup module start-up

[0237] After the central monitoring unit completes fault diagnosis, it immediately performs the following operations:

[0238] If the failure is determined to be a negative pressure failure: the negative pressure failure alarm will be activated, the on-site audible and visual alarm will issue a rapid red alarm (frequency 3 times / second), the HMI interface will pop up a red pop-up window displaying "Main negative pressure module failure! Start the backup module", and a remote maintenance notification will be pushed, indicating the faulty module number and possible cause;

[0239] If the problem is determined to be negative pressure attenuation: a negative pressure attenuation prompt will be activated, the on-site audible and visual alarm will issue an intermittent yellow alarm (frequency 1 time / second), a yellow pop-up window will appear on the HMI interface displaying "Main negative pressure module attenuation! Start backup module", and a remote maintenance notification will be pushed. No shutdown is required, only prompts for subsequent maintenance.

[0240] A start command is sent synchronously to the backup module, and the backup module inverter is powered on and enters standby operation mode.

[0241] (3) Power synchronization and main / standby parallel switching

[0242] To avoid abnormal paper cup posture caused by sudden pressure changes in the adsorption gas path during switching, a smooth transition logic of "power synchronization → parallel gas supply → main module shutdown" is adopted for switching:

[0243] 1. Power Synchronization Control: The central monitoring unit reads the real-time power P_main of the current main negative pressure module, i.e., P_max=1.35kW, and sends a "power follow" command to the standby module inverter. The standby module increases its power at a rate of 5% / second until the deviation between its output power P_standby and P_main is ≤±1%, i.e., 1.3365kW~1.3635kW. At this time, the pressure of the standby module tends to be consistent with the pressure of the main module.

[0244] 2. Parallel gas connection: After the power of the standby module is synchronized, the central monitoring unit sends an "open" command to the electromagnetic shut-off valve of the standby module. The valve opens quickly, and the standby module is connected to the gas circuit in parallel with the main module. The pressure of the adsorption gas circuit remains stable with fluctuations ≤ ±0.002MPa.

[0245] 3. Main Module Shutdown: After the parallel air supply stabilizes for 3 seconds, the central monitoring unit sends a "shutdown" command to the main module: ① The main module frequency converter reduces its power to 0 at a rate of 10% / second; ② The main module solenoid shut-off valve closes, completely cutting off the connection between the main module and the air circuit; ③ Record the main module's fault shutdown time, fault type, and operating parameters, and store them in the equipment fault log.

[0246] (4) Adjust the negative pressure power smoothly to the working power.

[0247] After the main module shuts down, the central monitoring unit initiates the power adjustment process of the backup module, targeting the preset working power P_work. In this embodiment, it is set to 70% of the rated power, i.e., 1.05kW, corresponding to a negative pressure of -0.05MPa, suitable for the regular adsorption requirements of paper cups.

[0248] Preset descent speed v_down: Set to 5% of the rated power per minute, i.e. 0.075kW / minute, to ensure a smooth power decrease and a gradual change in adsorption force, preventing the paper cup from shifting due to a sudden drop in pressure;

[0249] Adjustment execution: The standby module inverter gradually reduces the power at the rate of v_down, from P_max (1.35kW) to P_work (1.05kW). The entire adjustment process takes 4 minutes, i.e. (1.35-1.05)÷0.075=4.

[0250] Closed-loop verification: During the adjustment process, the negative pressure sensor of the main gas line provides real-time feedback on the pressure value. If the actual pressure deviates from the theoretical pressure corresponding to the target power by more than ±0.003MPa, the system automatically fine-tunes the descent speed (±1% / minute) until the deviation meets the requirements.

[0251] Adjustment complete: When the power of the standby module stabilizes at P_work and the pressure remains stable for 30 consecutive seconds, the central monitoring unit confirms that the adjustment is complete, the HMI interface updates the operating status of the standby module, and the alarm prompt changes to "Standby module is operating normally, main module is awaiting maintenance".

[0252] S14. Anomaly protection and redundancy assurance during the handover process

[0253] Switching Timeout Protection: If the backup module power synchronization timeout (failure to reach P_main±1% for more than 30 seconds) or valve opening timeout (failure to report opening status for more than 1 second), the central monitoring unit determines it as "switching abnormality" and immediately activates dual protection: ① Maintain the operation of the main module (avoid gas circuit pressure interruption); ② Issue an emergency alarm for "backup module switching failure" to prompt manual intervention;

[0254] Pressure surge protection: If the gas circuit pressure fluctuates by more than ±0.005MPa during the switching process, the system will immediately suspend the switching, the power of the standby module will remain unchanged, the main module will continue to run, and the switching process will be restarted after the pressure stabilizes.

[0255] Backup module fault redundancy: If the operating parameters (power, pressure) of the backup module are abnormal after it is started, the system will immediately issue a "backup module fault" alarm and allow manual activation of the manual emergency adsorption mode to control the gas pressure through the manual adjustment valve to avoid production line shutdown.

[0256] S15. Accurate identification and fault tracing of abnormal negative pressure conduction.

[0257] Once the main negative pressure module has been repaired / replaced or the main module has been repaired during the continuous operation of the backup negative pressure module, and the system has stably adjusted the power of the negative pressure modules (either the main module has resumed operation or the backup module continues to work) to the preset operating power and is running stably, it is necessary to further determine whether the fault originated from the negative pressure conduction link and was not a problem with the module itself. Targeted comparisons are used to accurately locate the root cause of the fault. The specific implementation is as follows:

[0258] (1) Setting of judgment parameters and logical basis

[0259] The central monitoring unit has built-in parameters for judging negative pressure conduction anomalies. The parameter settings strictly follow the principles of eliminating module faults and focusing on the conduction link. The specific configuration is as follows:

[0260] The preset reference number N_ref is set based on the maximum number of interceptions in historical operation and maintenance data when "the negative pressure module is normal and the transmission link is normal," and satisfies 0 < N_ref < preset number N0 (N0 = 10 times in S10). In this embodiment, by statistically analyzing 50 sets of production data with "module normal + transmission normal," it is found that the maximum number of interceptions within a 5-minute statistical period in this scenario is 2 times. Therefore, the preset reference number N_ref is set to 3 times, reserving 1 time for redundancy to avoid false triggering due to normal fluctuations. It supports adjustable calibration of 1-5 times through the HMI parameter configuration module to adapt to the differences in transmission efficiency of different production lines.

[0261] Power stability judgment criteria: After the power of the negative pressure module drops to the preset working power P_work (in this embodiment, the preset working power P_work is 1.05kW, corresponding to a negative pressure value of -0.05MPa), the actual negative pressure value fluctuates within ≤±0.003MPa for 30 consecutive seconds, and the power value fed back by the frequency converter deviates from the target working power by ≤±2%. This is judged as "power stable operation", and the conduction anomaly judgment process can be started. If the stability standard is not met, the system delays the judgment until the stability conditions are met before starting the statistics.

[0262] Statistical cycle reuse: The statistical cycle for determining transmission anomalies is consistent with the statistical cycle for interception counts, i.e., 5 minutes, to ensure the continuity and comparability of statistical data and avoid judgment deviations caused by cycle differences.

[0263] (2) Triggering conditions and execution process for transmission anomaly determination

[0264] The activation of the conduction anomaly detection process requires two prerequisites: ① The negative pressure module has been replaced / repaired and has been stably reduced to its operating power, reaching stable operating standards; ② The system has exited the S12-S14 master / slave switchover process and entered normal production monitoring status. The specific execution steps are as follows:

[0265] 1. Statistical cycle start: After the preconditions are met, the central monitoring unit automatically starts the first transmission anomaly judgment statistical cycle, and simultaneously activates the interception count statistics module. Following the effective interception counting principle in S10, the effective interception count N_con is recorded in real time within this cycle.

[0266] 2. Data Comparison and Result Determination: After the statistical period ends, the central monitoring unit directly compares the number of effective interceptions N_con with the preset reference number N_ref:

[0267] If N_con > N_ref, such as N_con ≥ 4 times > 3 times in this embodiment, it indicates that even if the negative pressure module itself is operating normally (power and negative pressure values ​​meet the standards), there is still a high-frequency delivery anomaly. Excluding module malfunctions, the root cause of the fault is determined to be an abnormality in the negative pressure conduction link. Possible fault points include: damage and leakage of the adsorption gas pipeline, loose gas pipeline joints, blockage / aging of the adsorption tool suction cup, and uneven adsorption force caused by the relative positional offset between the conveying guide rail and the adsorption tool.

[0268] If N_con≤N_ref, such as N_con≤3 times in this embodiment, it indicates that both the negative pressure module and the conduction link are operating normally, the transmission abnormality has been effectively resolved, the system exits the conduction abnormality judgment process, and resumes the normal interception count statistics and negative pressure power adaptive adjustment, such as the S10-S11 process.

[0269] (3) Abnormal negative pressure conduction prompts and troubleshooting guidance

[0270] Once an abnormality in negative pressure conduction is detected, the central monitoring unit immediately activates a targeted alarm mechanism to ensure that maintenance personnel can quickly locate the fault, as detailed below:

[0271] Multi-level alarm feedback:

[0272] 1. The on-site audible and visual alarm emits a "constant red light + intermittent alarm sound (2 times / second)", which can be distinguished from the negative pressure module fault alarm, making it easier for staff to quickly identify the fault type;

[0273] 2. A dedicated alarm pop-up window appears on the HMI (Human Machine Interface) with the title "Negative Pressure Conduction Abnormality". The pop-up displays the following information: Judgment Statistical Period (XX:XX-XX:XX), Actual Interception Count N_con, Reference Count N_ref, Current Negative Pressure Module Operating Parameters (Power, Actual Negative Pressure Value), and lists clear troubleshooting directions (sorted by priority): ① Check for leaks in the adsorption gas pipeline and joints; ② Clean / replace the adsorption fixture suction cups; ③ Calibrate the relative position of the delivery guide rail and the adsorption fixture; ④ Check for blockages in the gas filter.

[0274] 3. The remote operation and maintenance platform pushes alarm information to designated staff, including the fault type, troubleshooting suggestions and the current operating status of the production line, and supports staff to report the troubleshooting progress via mobile devices.

[0275] Production line status control: After an alarm is triggered, the production line maintains normal conveying speed. Transmission abnormalities are mostly local problems and do not require shutdown. However, the system will continue to count the number of interceptions in subsequent statistical cycles. If N_con > N_ref is still satisfied for two consecutive cycles, the production line will automatically reduce the conveying speed to 70% of the normal speed to avoid the accumulation of batch abnormalities until the fault is resolved.

[0276] (4) Reset and status restoration after troubleshooting

[0277] After maintenance personnel have completed troubleshooting of the transmission process, such as repairing leaking pipes, replacing suction cups, and calibrating positions, they can reset the system by following these steps:

[0278] 1. Staff click the "Transmission Anomaly Troubleshooting Completed" button on the HMI interface, submit the troubleshooting results, and can optionally fill in the cause of the fault and the handling method;

[0279] 2. After receiving the reset signal, the central monitoring unit stops the audible and visual alarms and remote notifications, and closes the HMI alarm pop-up window;

[0280] 3. Automatically start a new statistical cycle and re-verify the conduction anomaly: If N_con≤N_ref in this cycle, the fault is determined to be eliminated and the system fully resumes the normal monitoring process; if N_con>N_ref, the system triggers an alarm again, prompting the staff to conduct a second investigation, and at the same time locks the operating data of the relevant conduction links, such as the gas pressure change curve and the adsorption tool action log, to provide data support for in-depth investigation.

[0281] This application also discloses a real-time monitoring system for paper cup production, including a processor that executes the steps of the real-time monitoring method for paper cup production as described in any of the above embodiments.

[0282] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A method for real-time monitoring of paper cup production, characterized in that, Includes the following steps: A first optical sensor is installed at the vertical feed inlet of the vertical conveyor line. The first optical sensor detects the paper cups being fed and conveyed downward to generate first optical data. The first conveying timestamp and the first conveying position are extracted from the first optical data. A second optical sensor is installed on the vertical conveyor line. The second optical sensor detects the paper cups undergoing quality inspection to generate second optical data. The second conveying timestamp and the second conveying position are extracted from the second optical data. The visual quality inspection equipment is located next to the vertical conveyor line and corresponds to the position of the second optical sensor. A first continuous timeline is calculated based on the first continuous delivery timestamp, and a second continuous timeline is calculated based on the second continuous delivery timestamp. The paper cups corresponding to the timestamps are aligned with the first and second continuous timelines. The time error between the first and second continuous timelines and the preset corresponding interval is calculated. If the time error is greater than the preset time error, a paper cup delivery abnormality prompt is issued. Calculate a first continuous position line based on the first conveying position, calculate a second continuous position line based on the second conveying position, align the paper cups corresponding to the conveying positions with the first and second continuous position lines, calculate the positional error of the first and second continuous position lines within the corresponding interval, and if the positional error is greater than the preset positional error, issue a paper cup position anomaly warning. Based on the paper cup conveying abnormality prompts and paper cup position abnormality prompts, the quality inspection results within the corresponding range are extracted. If all the quality inspection results are qualified, an adsorption abnormality alarm is triggered; otherwise, a paper cup abnormality alarm is triggered.

2. The method for real-time monitoring of paper cup production according to claim 1, characterized in that, A third optical sensor is located between the first and second optical sensors, and the distance between the third optical sensor and the vertical conveyor line is greater than the maximum distance between the paper cup and the vertical conveyor line. The third optical sensor detects the paper cup and generates an abnormal delivery position; Record the generation timestamp of the abnormal delivery location, calculate the backtrack timestamp based on the generation timestamp and the preset backtrack duration, and extract the corresponding quality inspection results based on the backtrack time; A material guiding mechanism is installed below the vertical conveyor line; if the quality inspection result is normal, the material guiding mechanism is controlled to guide the paper cup corresponding to the abnormal conveying position into the preset qualified discharge port; otherwise, the material guiding mechanism is controlled to guide the paper cup corresponding to the abnormal conveying position into the preset unqualified discharge port.

3. The method for real-time monitoring of paper cup production according to claim 2, characterized in that, The material guiding mechanism includes a guide plate that is suspended at the lower end of the vertical conveyor line. The guide plate is connected to a telescopic component, which allows the guide plate to be in either a first or a second material guiding position. The first guide position corresponds to the qualified discharge port, and the second guide position corresponds to the unqualified discharge port.

4. The method for real-time monitoring of paper cup production according to claim 3, characterized in that, A microswitch is installed on the guide plate, which is used to sense paper cups falling onto the guide plate; Once the micro switch is triggered, a trigger timestamp is generated. Obtain the recording time period between the trigger timestamps and for a preset recording duration, and extract the paper cup delivery abnormality prompts and paper cup position abnormality prompts within the recording time period; if no paper cup delivery abnormality prompts and paper cup position abnormality prompts are extracted, then a foreign object interference prompt is issued; If only abnormal paper cup delivery or abnormal paper cup position is detected, then an abnormal optical sensor warning will be issued.

5. The method for real-time monitoring of paper cup production according to claim 2, characterized in that, The method also includes the following steps: Based on the generated timestamp and the preset backtracking duration, the time period after the generated timestamp is extracted as the backtracking time period, and the quality inspection results in the backtracking time period are extracted. If there are any non-compliant results in the quality inspection, the paper cups corresponding to the non-compliant results will be marked as the affected targets; A material-cutting mechanism is installed at the non-conforming discharge port of the vertical conveyor line; when the affected target moves to the non-conforming discharge port, the material-cutting mechanism is controlled to guide the paper cup corresponding to the non-conforming result into the preset re-inspection discharge port.

6. The method for real-time monitoring of paper cup production according to claim 5, characterized in that, The method also includes the following steps: The number of times the material is guided by the cutting mechanism within the preset statistical time period is the interception count. If the interception count is greater than the preset number, an alarm will be triggered to indicate an abnormality in the paper cup conveying process.

7. The method for real-time monitoring of paper cup production according to claim 6, characterized in that, The method also includes the following steps: If the number of interceptions is less than the set number, the interception feedback value is calculated based on the number of interceptions and the set number. The negative pressure power of the control negative pressure device is adjusted according to the interception feedback value. When the interception feedback value increases, the negative pressure power increases; when the interception feedback value decreases, the negative pressure power decreases.

8. The method for real-time monitoring of paper cup production according to claim 7, characterized in that, The method also includes the following steps: When the negative pressure power increases to the preset maximum power value, the rate of change of the interception feedback value is calculated within the subsequent preset temporary duration. If the trend of change is greater than the preset comparison trend, a negative pressure failure alarm will be triggered, and the backup negative pressure module will be activated. Otherwise, issue a negative pressure attenuation warning and activate the backup negative pressure module; The backup negative pressure module is connected in parallel with the current negative pressure module. After the power of the backup negative pressure module is the same as that of the current negative pressure module, the current negative pressure module is turned off. The power of the negative pressure module is reduced to the preset operating power according to the preset descent speed.

9. The method for real-time monitoring of paper cup production according to claim 8, characterized in that, The method also includes the following steps: After replacing the negative pressure module, the power of the negative pressure module was reduced to the operating power. If the number of interceptions exceeds the preset reference number, a negative pressure conduction anomaly warning will be issued; Where 0 < reference number < set number.

10. A real-time monitoring system for paper cup production, characterized in that, The device includes a processor that performs the steps of the real-time monitoring method for paper cup production as described in any one of claims 1-9.

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