A cable protection pipe raw material mixing intelligent blending and constant temperature control method and system

Abstract

The present application relates to a kind of cable protection pipe raw material mixing intelligent deployment and constant temperature control method and system, it is related to the field of cable protection pipe raw material mixing, it includes obtaining protection pipe raw material and mixing demand;Find demand raw material, raw material weight, heat mixing sequence and heat mixing temperature;Get proportioning raw material;Get the maximum temperature difference between each real-time storage temperature;Find temperature difference threshold and preheating temperature;If the maximum temperature difference is less than temperature difference threshold, proportioning raw material is placed in heat mixing machine and heated to obtain finished product dry mixture;If the maximum temperature difference is greater than temperature difference threshold, obtain material class, the real-time storage temperature of the same material class is sorted from low to high to obtain the preheating sequence of proportioning raw material in the same material class;According to preheating sequence, proportioning raw material is placed in preheating device in turn and heated;Proportioning raw material of all material classes is placed in heat mixing machine and heated to obtain finished product dry mixture.The present application has the effect of reducing the influence of uniform heating overall temperature imbalance.

Description

Technical Field

[0001] This invention relates to the field of raw material mixing for cable protection pipes, and in particular to an intelligent mixing and constant temperature control method and system for raw material mixing for cable protection pipes. Background Technology

[0002] In the production of cable protection pipes, resin, inorganic fillers, and various functional additives need to be mixed and formulated, and a uniform dry-mix material is obtained through hot mixing for subsequent extrusion molding. The temperature control of raw material mixing directly affects the mixing effect and the quality of the finished pipe. Therefore, stable constant temperature control is the key to the mixing process.

[0003] Currently, when processing raw materials for cable protection pipes, the weighed large and small materials are usually put into the hot mixing equipment at once, and the temperature is raised uniformly by stirring friction and auxiliary heating of the cavity. Production often adopts fixed time control and simple wall temperature detection. Weighing and batching and temperature control are independent of each other and there is no coordinated adjustment mechanism.

[0004] Regarding the aforementioned technologies, in actual production, the suitable storage temperatures for resins, bulk fillers, and functional additives vary, resulting in significant initial temperature differences before each material is added. Current methods directly mix hot and cold materials and heat them simultaneously. However, this initial temperature difference leads to uneven overall temperature rise, easily causing incomplete mixing, localized overheating and deterioration, and batch-to-batch quality fluctuations, affecting production stability. Therefore, there is room for improvement. Summary of the Invention

[0005] To reduce the impact of uneven overall temperature rise caused by initial temperature difference, this invention provides a method and system for intelligent mixing and constant temperature control of raw materials for cable protection pipes.

[0006] In a first aspect, the present invention provides a method for intelligent mixing and constant temperature control of raw materials for cable protection pipes, employing the following technical solution: A method for intelligent mixing and constant temperature control of raw materials for cable protection pipes includes: Step 1: Obtain the raw materials and mixing requirements for the protective tubes stored in each constant temperature storage tank; Step 2: Based on the mixing requirements and the preset raw material ratio library, find the required raw materials, the corresponding raw material weights, the corresponding hot mixing sequence and hot mixing temperature of the required raw materials; Step 3: Weigh the raw materials for the protective tube according to the required raw material weight to obtain the proportioned raw materials; Step 4: Obtain the real-time storage temperature of each proportion of raw materials and calculate the maximum temperature difference between each real-time storage temperature; Step 5: Find the temperature difference threshold and preheating temperature based on the raw material ratio and the preset raw material temperature database; Step 6: If the maximum temperature difference is less than the temperature difference threshold, put the raw materials into the hot mixer in the hot mixing order and stir and heat to the hot mixing temperature to obtain the finished dry mixture. Step 7: If the maximum temperature difference is greater than the temperature difference threshold, classify the raw materials according to the preset raw material database to obtain the material categories, and sort the real-time storage temperature of the same material category from low to high to obtain the preheating order of the raw materials in the same material category. Step 8: According to the preheating sequence, put the proportioned raw materials into the preset preheating device in sequence for stirring and heating. When the previous proportioned raw material is heated to the real-time storage temperature corresponding to the next proportioned raw material, put the next proportioned raw material in, until the next proportioned raw material is no longer available. Then stir and heat the proportioned raw materials of the same material category to the preheating temperature. Step 9: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

[0007] By adopting the above technical solution, the raw materials for the protective tube are obtained according to the mixing requirements and weighed to obtain the proportioned raw materials; the maximum temperature difference of the real-time storage temperature of each proportioned raw material is calculated, and the temperature difference threshold and preheating temperature are found from the raw material temperature database; if the maximum temperature difference is less than the threshold, it is directly heated to the heating temperature; if it is greater than the threshold, the proportioned raw materials are classified according to the major material categories, and within the same major category, they are preheated step by step to the preheating temperature from low to high. Finally, all major categories of raw materials are heated in sequence to obtain the finished dry mixture. This solves the problem of uneven overall temperature rise caused by direct mixing and unified heating of cold and hot materials, which leads to insufficient mixing and local overheating and deterioration of materials. It achieves the effect of heating the proportioned raw materials of the same major material category step by step and finally mixing and heating all major material categories.

[0008] Optionally, methods for finding the temperature difference threshold and preheating temperature based on the proportioned raw materials and a preset raw material temperature database include: Step 50: Find the corresponding thermosensitive data of the raw materials according to the proportioned raw materials and the preset raw material temperature library. The thermosensitive data includes the thermal decomposition temperature and the maximum allowable contact temperature difference. Step 51: Multiply the thermal decomposition temperature of each raw material in the formula with the preset first safety factor to obtain the upper limit of the safe temperature; Step 52: Screen the upper limit of safe temperature to obtain the minimum upper limit of temperature and the corresponding minimum proportion of raw materials; Step 53: Calculate the minimum temperature difference by subtracting the real-time storage temperature corresponding to the minimum temperature limit and the minimum proportion of raw materials; Step 54: If the maximum allowable contact temperature difference is less than the minimum temperature difference, then the maximum allowable contact temperature difference is used as the temperature difference threshold and output. Step 55: If the maximum allowable contact temperature difference is not less than the minimum temperature difference, then use the minimum temperature difference as the temperature difference threshold and output it. Step 56: Multiply the minimum temperature limit by the preset second safety factor to obtain the safe preheating limit; Step 57: If the hot mixing temperature is lower than the safe preheating upper limit, then the hot mixing temperature is used as the preheating temperature and output. Step 58: If the hot mixing temperature is not less than the safe preheating upper limit, then use the safe preheating upper limit as the preheating temperature and output it.

[0009] By adopting the above technical solution, the upper limit of the safe temperature is calculated based on the thermal decomposition temperature of each raw material in the formula. The minimum value is taken to obtain the minimum upper limit of the temperature and the corresponding raw material. The minimum temperature difference is obtained by subtracting the real-time temperature from the upper limit. The smaller value between the maximum allowable contact temperature difference and the minimum temperature difference is taken as the temperature difference threshold. The upper limit of the minimum temperature is multiplied by the safety factor to obtain the upper limit of safe preheating. The smaller value between the upper limit of safe preheating and the heat mixing temperature is taken as the preheating temperature. This achieves the effect of determining the temperature difference threshold and the preheating temperature based on the thermal sensitivity characteristics of the raw materials in the formula, avoiding the problem of thermal shock or inadequate preheating caused by blindly setting based on experience.

[0010] Optionally, it also includes a method for handling situations where the maximum temperature difference exceeds a temperature difference threshold, the method further including: Step 70: Combine two adjacent raw materials in the same material category according to the preheating sequence to obtain adjacent raw material groups, and define the raw materials in the adjacent raw material groups as preceding raw materials and subsequent raw materials; Step 71: Calculate the average temperature of adjacent raw material groups by taking the average of their real-time storage temperatures. Step 72: Stir and heat the two proportioned raw materials in adjacent raw material groups to the adjacent average temperature to obtain adjacent combined raw materials; Step 73: Define the adjacent average temperature corresponding to the previous adjacent combination of raw materials as the preceding average temperature, and define the adjacent average temperature corresponding to the next adjacent combination of raw materials as the following average temperature. Step 74: According to the preheating sequence, put adjacent combination raw materials into the preheating device in sequence for stirring and heating. When the previous adjacent combination raw material is heated to the average temperature of the subsequent sequence, put the next adjacent combination raw material in, until the next adjacent combination raw material is no longer present. Then stir and heat the proportion of raw materials of the same material category to the preheating temperature. Step 75: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

[0011] By adopting the above technical solution, adjacent raw materials in the preheating sequence are combined in pairs to obtain adjacent raw material groups and the adjacent average temperature is calculated; the adjacent raw material groups are mixed to obtain adjacent combined raw materials; then, according to the preheating sequence and the adjacent average temperature, the adjacent combined raw materials are put into the preheating device step by step for preheating and finally mixed into the finished dry mixture. This solves the problem of low efficiency in preheating raw materials in the same material category step by step, and achieves the effect of improving efficiency through combined preheating.

[0012] Optional, also includes: Step 730: Subtract the preceding average temperature from the subsequent average temperature to obtain the adjacent average temperature difference; Step 731: If the adjacent average temperature difference is greater than the preset adjacent temperature difference threshold, the adjacent average temperature difference that is greater than the preset adjacent temperature difference threshold is defined as the threshold-exceeding adjacent temperature difference. Step 732: Define the preceding average temperature corresponding to the adjacent temperature difference exceeding the threshold as the preceding temperature exceeding the threshold, and define the subsequent average temperature corresponding to the adjacent temperature difference exceeding the threshold as the subsequent temperature exceeding the threshold. Step 733: Combine the preceding raw material corresponding to the preceding temperature above the threshold and the subsequent raw material corresponding to the subsequent temperature above the threshold to obtain the preceding combined raw material group; combine the subsequent raw material corresponding to the preceding temperature above the threshold and the preceding raw material corresponding to the subsequent temperature above the threshold to obtain the subsequent combined raw material group. Step 734: Calculate the preceding combination temperature of the preceding combination raw material group by taking the average of the real-time storage temperatures corresponding to the preceding combination raw material group; calculate the subsequent combination temperature of the subsequent combination raw material group by taking the average of the real-time storage temperatures corresponding to the subsequent combination raw material group. Step 735: Heat the proportioned raw materials in the preceding combination raw material group to the preceding combination temperature and then mix them; heat the proportioned raw materials in the subsequent combination raw material group to the subsequent combination temperature and then mix them. Step 736: In adjacent average temperatures, replace the preceding temperature that exceeds the threshold with the preceding combined temperature, and replace the following temperature that exceeds the threshold with the following combined temperature. Step 737: Sort adjacent average temperatures from low to high to obtain the current preheating order of adjacent combinations of raw materials in the same material category; Step 738: Proceed to step 74 according to the current preheating sequence; Step 739: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

[0013] By adopting the above technical solution, the temperature difference between adjacent raw materials is calculated. If it exceeds the threshold, the raw materials are broken up and cross-recombined to obtain two new sets of raw materials and their respective combination temperatures are calculated. After being reordered according to temperature, they are preheated step by step and then heated in combination to obtain the finished dry mixture. This solves the problem that the adjacent average temperature difference between raw materials is too large and it is difficult to mix them directly. It achieves the effect of breaking up and cross-recombining the raw materials in the original adjacent raw materials and then heating them step by step.

[0014] Optionally, it also includes a method for distributing and heating the preceding and subsequent batches of raw materials, the method comprising: Step 7330: Subtract the previous combination temperature from the subsequent combination temperature to obtain the average temperature difference of the combination; Step 7331: If the combined average temperature difference is greater than the preset adjacent temperature difference threshold, then the preceding combined raw material group and the following combined raw material group are disassembled to obtain independent raw materials. Step 7332: Sort the adjacent combined raw materials and the independent raw materials in ascending order according to the adjacent average temperature and the real-time storage temperature of the independent raw materials to obtain the mixing order of the adjacent combined raw materials and the independent raw materials; Step 7333: According to the mixing order, adjacent combined raw materials and independent raw materials are put into the preheating device in sequence for stirring and heating. The previous adjacent combined raw material or independent raw material is heated to the average temperature of the subsequent sequence or the real-time storage temperature corresponding to the independent raw material, until the next adjacent combined raw material or independent raw material is no longer present. Then, the proportioned raw materials of the same material category are stirred and heated to the preheating temperature.

[0015] By adopting the above technical solution, if the temperature difference between the two groups of combined raw materials after recombination still exceeds the threshold, they are broken down into independent raw materials; the remaining adjacent combinations and independent raw materials are sorted by temperature and preheated in sequence, which solves the problem that the average temperature difference of the combined raw materials after cross-recombination is too large to mix directly, and realizes the effect of automatically adjusting the ratio of raw material combinations or preheating them independently according to the adjacent average temperature difference.

[0016] Optionally, it also includes an optimization method for the raw material ratio library, which includes: Step 20: When the safe preheating upper limit is less than the hot mixing temperature, the preheating safety margin is obtained by subtracting the hot mixing temperature from the safe preheating upper limit. Step 21: If the preheating safety margin is greater than the preset optimization threshold, find alternative raw materials in the raw material ratio library based on the minimum ratio of raw materials; Step 22: Based on the alternative raw materials, find the corresponding thermal decomposition temperature of the alternative raw materials in the raw material temperature database; Step 23: Screen the alternative thermal decomposition temperatures to obtain the highest alternative thermal decomposition temperature, and replace the minimum ratio raw material with the alternative raw material corresponding to the highest alternative thermal decomposition temperature to output the latest required raw material. Step 24: Update the required raw materials for the mixing requirements in the raw material ratio library to the latest required raw materials.

[0017] By adopting the above technical solution, when the upper limit of safe preheating is lower than the hot mixing temperature and the preheating safety margin exceeds the threshold, the alternative raw material with the best thermal stability is found, the raw material with the smallest ratio is replaced, and the required raw materials in the raw material ratio library are updated. This solves the problem that the preheating temperature reaches the hot mixing temperature with a large temperature range and is difficult to heat stably in the current formula due to the poor thermal stability of the raw materials. It achieves the effect of automatically and rationally adjusting the current formula.

[0018] Optional, also includes: Step 210: If no alternative raw material is available, perform a pre-set raw material pretreatment on the minimum raw material to increase the thermal decomposition temperature of the minimum raw material until the preheating safety margin is not greater than the optimization threshold. Step 211: If a substitute raw material is available, multiply the highest substituted thermal decomposition temperature by the first safety factor to obtain the upper limit of the substituted temperature; Step 212: Define the upper limit of safe temperature for the raw materials in the latest demand list after removing the alternative raw materials as the upper limit of constant temperature; Step 213: Filter the upper limit of the substitutable temperature and the upper limit of the constant temperature to obtain the current minimum upper limit and the current minimum raw material corresponding to the current minimum upper limit; Step 214: Multiply the current minimum upper limit and the second safety factor to obtain the safe preheating upper limit; Step 215: When the safe preheating upper limit is still less than the hot mixing temperature, the preheating safety margin is obtained by subtracting the hot mixing temperature from the safe preheating upper limit. Step 216: If the preheating safety margin is still greater than the optimization threshold, perform a preset raw material pretreatment on the current minimum raw material to increase the thermal decomposition temperature of the current minimum raw material until the preheating safety margin is no greater than the optimization threshold.

[0019] By adopting the above technical solution, the minimum proportion raw material is pre-treated when there is no substitute; and the current minimum raw material is pre-treated when there is a substitute but the margin still exceeds the threshold after replacement. In both cases, the margin is processed until it meets the standard, which solves the problem that the temperature range between the preheating temperature and the hot mixing temperature is large and the heating is difficult to stabilize after replacing the proportion raw material due to the poor thermal stability of the proportion raw material.

[0020] Optionally, it also includes a method for verifying the weight of the raw materials in the formulation, the method comprising: Step 30: Based on the proportioned raw materials, real-time storage temperature, and hot mixing temperature, find the heating weight change coefficient of the proportioned raw materials from the real-time storage temperature to the hot mixing temperature in the preset temperature and weight database; Step 31: Multiply the weight of each ingredient by the corresponding heating weight change coefficient and sum them to obtain the theoretical finished product weight; Step 32: Obtain the actual weight of the finished dry mix; Step 33: Subtract the theoretical finished product weight from the actual finished product weight to obtain the weight deviation; Step 34: If the weight deviation is greater than the preset weight threshold, output the preset raw material weight abnormality signal.

[0021] By adopting the above technical solution, the theoretical weight of the finished product is calculated based on the heating weight change coefficient and compared with the actual weight. If the deviation exceeds the threshold, a weight abnormality signal is output. This solves the problem of not being able to verify that the actual weight after hot mixing is too different from the theoretical weight, and achieves the effect of prompting abnormal actual finished product weight.

[0022] Optionally, a method for monitoring real-time storage temperature is also included, the method comprising: Step 40: Locate the corresponding normal storage range in the preset storage temperature warehouse according to the proportion of raw materials; Step 41: If the real-time storage temperature does not fall within the normal storage range, define the real-time storage temperature that does not fall within the normal storage range as the abnormal storage temperature, and define the raw materials corresponding to the abnormal storage temperature as the abnormal raw materials. Step 42: Based on the abnormal ratio of raw materials, find the alternative functional raw materials in the raw material ratio library; Step 43: Update the abnormal ratio raw materials to the backup functional raw materials and output them.

[0023] By adopting the above technical solution, when the real-time storage temperature of the raw materials is abnormal, the system searches for backup functional raw materials in the raw material ratio library and replaces the abnormal raw materials with the backup functional raw materials. This solves the problem of not being able to perform mixing operations when the constant temperature storage of the raw materials fails, and realizes the adaptive replacement of abnormal raw materials.

[0024] Secondly, this invention provides an intelligent mixing and constant temperature control system for cable protection pipe raw materials, employing the following technical solution: A smart mixing and temperature control system for cable protection pipe raw materials includes: The acquisition module is used to acquire information such as raw materials for the protective tube, mixing requirements, real-time storage temperature, and actual finished product weight. The memory is used to store the program for the intelligent mixing and constant temperature control method of cable protection pipe raw materials as described above; The processor loads and executes programs from memory.

[0025] In summary, the present invention has at least one of the following beneficial technical effects: It solves the problem of uneven overall temperature rise caused by direct mixing and unified heating of cold and hot materials, resulting in insufficient mixing and local overheating and deterioration of materials. It achieves the effect of heating the raw materials of the same material category step by step and finally mixing and heating all material categories. This solves the problem of low efficiency in sequential preheating of raw materials within the same material category, and achieves the effect of improving efficiency through combined preheating. It solves the problem that the average temperature difference of the combined raw materials after cross-recombination is too large to mix directly, and realizes the effect of automatically adjusting the ratio of raw material combinations or preheating them independently according to the adjacent average temperature difference. Attached Figure Description

[0026] Figure 1 This is a flowchart of a method for intelligent mixing and constant temperature control of raw materials for cable protection pipes according to an embodiment of this application; Figure 2 This is a flowchart of the processing method in this application embodiment for when the maximum temperature difference is greater than the temperature difference threshold; Figure 3 This is a flowchart of the distribution and heating method of the preceding and subsequent raw material groups in the embodiments of this application. Detailed Implementation

[0027] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0028] This invention discloses a method for intelligent mixing and constant temperature control of raw materials for cable protection pipes. (Refer to...) Figure 1 A method for intelligent mixing and constant temperature control of raw materials for cable protection pipes includes: Step 1: Obtain the raw materials and mixing requirements for the protective tubes stored in each constant temperature storage tank.

[0029] A constant temperature storage tank refers to a raw material storage tank with temperature control function, which is preset by those skilled in the art, wherein the temperature of each tank is independent and constant.

[0030] The raw materials for cable protection pipes refer to all the raw materials used in their production, including base resins (such as PVC, CPVC, and PE), inorganic fillers, and various functional additives (plasticizers, stabilizers, and lubricants). Each raw material is stored in a corresponding temperature-controlled storage tank. By reading the material codes and storage location information of each tank pre-set by those skilled in the art, a list of currently available raw materials for cable protection pipes is obtained. Specifically, the material codes and storage location information of each tank are pre-assigned by those skilled in the art and mapped to their location information, thus obtaining the material codes and storage location information for each tank.

[0031] Mixed production requirements refer to the cable protection pipes that need to be produced in this production run. These requirements are obtained through pre-planned production schedules or input by operators.

[0032] Step 2: Based on the mixing requirements and the preset raw material ratio library, find the required raw materials, the corresponding raw material weights, the corresponding hot mixing sequence, and the hot mixing temperature.

[0033] The raw material ratio library stores the mapping relationship between mixing requirements and required raw materials, raw material weights, hot mixing sequence, and hot mixing temperature. The raw material ratio library was pre-established by those skilled in the art based on the formula documents for various cable protection pipe models, where the formula documents originate from standard formula sheets or process cards issued by the internal R&D department. Each record in the database includes: the name of the mixing requirement (i.e., product model or formula code), a list of required raw materials, the weight ratio of each required raw material, the hot mixing sequence, and the hot mixing temperature.

[0034] The required raw materials refer to the specific raw materials needed for the blending requirements of this production. They can be obtained by entering the blending requirements into the raw material ratio library.

[0035] The raw material weight refers to the standard weight that each required raw material should be weighed according to the formula in this mixing process, which can be obtained by entering the mixing requirements into the raw material ratio library.

[0036] The hot mixing sequence refers to the order in which various raw materials are added to the hot mixer, usually larger materials first, then smaller materials. The hot mixing sequence can be obtained by entering the mixing requirements into the raw material ratio database.

[0037] The hot mixing temperature refers to the final temperature that needs to be reached during the final mixing in the hot mixer. It can be obtained by entering the mixing requirements into the raw material ratio library.

[0038] Step 3: Weigh the raw materials for the protective tube according to the required raw material weight to obtain the raw material ratio.

[0039] The raw materials for mixing refer to the materials that are actually obtained after weighing and are prepared for mixing. The raw materials for mixing are obtained by weighing each raw material according to its weight.

[0040] Step 4: Obtain the real-time storage temperature of each proportion of raw materials and calculate the maximum temperature difference between each real-time storage temperature.

[0041] Real-time storage temperature refers to the real-time temperature of the raw materials in the constant-temperature storage tank. Each constant-temperature storage tank is equipped with a temperature sensor. During or after weighing and dispensing, the temperature sensor readings are used to determine the real-time storage temperature of the raw material.

[0042] Maximum temperature difference refers to the difference between the highest and lowest temperatures in the real-time storage temperature of each proportion of raw materials.

[0043] Step 5: Find the temperature difference threshold and preheating temperature based on the raw material ratio and the preset raw material temperature database.

[0044] The raw material temperature database contains mapping relationships between each proportion of raw materials and the thermosensitive data of each proportion. The raw material temperature database was established by those skilled in the art based on data from raw material suppliers.

[0045] The temperature difference threshold refers to the maximum allowable storage temperature difference between raw materials in the formula. The temperature difference threshold is obtained by finding the thermal decomposition temperature and the maximum allowable contact temperature difference of the raw materials in the thermal data of the raw material temperature database, and then calculating, screening and comparing them. The specific acquisition steps are described in steps 50 to 55 below.

[0046] Preheating temperature refers to the target temperature to which the materials are heated during the preheating stage. The preheating stage involves gradually preheating the raw materials before they are added to the hot mixer. This is because different materials may have different storage temperatures in the constant-temperature storage tank; if materials with large temperature differences are directly added to the hot mixer, the low-temperature materials will experience thermal shock, while the high-temperature materials may overheat locally, leading to the failure of heat-sensitive additives or uneven plasticization. The preheating stage mainly uses a step-by-step heating method to ensure that materials of the same category reach a uniform preheating temperature before being added to the hot mixer, eliminating initial temperature differences between materials and avoiding thermal shock. The specific steps for obtaining the preheating temperature are detailed in steps 50 to 58 below.

[0047] Step 6: If the maximum temperature difference is less than the temperature difference threshold, put the raw materials into the hot mixer in the hot mixing order and stir and heat them to the hot mixing temperature to obtain the finished dry mixture.

[0048] A hot mixer is a device for mixing and processing raw materials for cable protection pipes. It works by stirring the raw materials to induce friction, combined with auxiliary heating within the chamber to raise the temperature uniformly. The hot mixer mainly consists of a pot body, stirring paddle, transmission device, heating jacket, pot lid, and discharge port. The pot body is a multi-layered stainless steel structure, and the jacket is filled with heat-conducting oil. Electric heating and the self-friction heat from stirring work together to raise the temperature of the materials. The pot lid uses a double seal, and the main shaft has multiple sealing devices to prevent powder leakage. The entire machine is controlled by a PLC; a typical model is the SRL-Z300 / 600 hot and cold mixing unit.

[0049] Finished dry mix refers to the final product obtained after being fully mixed in a hot mixer and reaching the hot mixing temperature. It is obtained by weighing the proportioned raw materials and putting them into the hot mixer in the hot mixing order, stirring and heating to the hot mixing temperature.

[0050] If the maximum temperature difference is less than the temperature difference threshold, it means that the real-time storage temperature difference of each proportion of raw materials is within the safe range, and direct mixing will not cause thermal shock to the heat-sensitive raw materials; the finished dry mixture is obtained by directly stirring and heating in the hot mixer according to the hot mixing sequence.

[0051] Step 7: If the maximum temperature difference is greater than the temperature difference threshold, classify the raw materials according to the preset raw material database to obtain the material categories, and sort the real-time storage temperature of the same material category from low to high to obtain the preheating order of the raw materials in the same material category.

[0052] The raw material database contains a mapping relationship between the proportioned raw materials and their corresponding material categories. The raw material database is established by those skilled in the art based on the physical properties of the proportioned raw materials, and each data entry includes the name of the proportioned raw material and its corresponding material category.

[0053] A material category refers to a collection of raw materials belonging to the same general category of ingredients. Material categories are distinguished based on the functional role and physical properties of the formulation, and typically include resins, fillers, plasticizers, stabilizers, and lubricants. Raw materials are grouped according to these categories, forming a single material category.

[0054] Preheating sequence refers to the heating order of raw materials within the same material category during preheating. The preheating sequence is obtained by sorting the real-time storage temperatures of the raw materials within the same material category from lowest to highest.

[0055] If the maximum temperature difference is greater than the temperature difference threshold, it means that the real-time storage temperature difference of each raw material exceeds the safe range. Direct mixing will cause thermal shock to the heat-sensitive raw materials. First, classify the raw materials according to their material categories, and sort the raw materials of the same category from low to high according to their real-time storage temperature to obtain the order of gradual preheating.

[0056] Step 8: According to the preheating sequence, put the proportioned raw materials into the preset preheating device in sequence for stirring and heating. When the previous proportioned raw material is heated to the real-time storage temperature corresponding to the next proportioned raw material, put the next proportioned raw material in, until the next proportioned raw material is no longer available. Then stir and heat the proportioned raw materials of the same material category to the preheating temperature.

[0057] A preheating device is a container with stirring and heating functions, which preheats each category of materials separately before they enter the hot mixer. The preheating device is pre-set by those skilled in the art. The device is equipped with temperature control and feeding valves, and can receive the proportioned raw materials in the preheating sequence and heat them step by step. The specific structure can be referred to the hot mixer.

[0058] This step involves preheating the raw materials of each material category to the preheating temperature in stages.

[0059] Step 9: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

[0060] Finally, all the raw materials in the same category that have been preheated to the same temperature (i.e., preheating temperature) are put into the hot mixer in the original hot mixing order and stirred and heated to the hot mixing temperature to obtain the finished dry mix.

[0061] The methods for finding the temperature difference threshold and preheating temperature based on the proportioned raw materials and a preset raw material temperature database include: Step 50: Find the corresponding thermosensitive data for the raw materials according to the proportioned raw materials and the preset raw material temperature library. The thermosensitive data includes the thermal decomposition temperature and the maximum allowable contact temperature difference.

[0062] Thermosensitive data refers to the characteristic parameters exhibited by raw materials when heated, including thermal decomposition temperature and maximum permissible contact temperature difference. Thermosensitive data is obtained by querying a raw material temperature database using the proportioned raw materials.

[0063] Thermal decomposition temperature refers to the temperature at which a raw material begins to undergo chemical decomposition under continuous heating conditions. It is obtained by querying thermally sensitive data from a raw material temperature database.

[0064] The maximum permissible contact temperature difference refers to the maximum temperature range that a raw material can withstand when it comes into instantaneous contact with another raw material at a different temperature without experiencing thermal failure. The maximum permissible contact temperature difference is obtained through thermistor data.

[0065] Step 51: Multiply the thermal decomposition temperature of each raw material by the preset first safety factor to obtain the upper limit of the safe temperature.

[0066] The first safety factor is a coefficient that converts the thermal decomposition temperature to the upper limit of the safe temperature. The first safety factor is preset by those skilled in the art based on experience and the physical properties of the raw materials.

[0067] The upper limit of safe temperature refers to the highest temperature that the raw materials in the formula are allowed to reach during processing. It is obtained by multiplying the thermal decomposition temperature by the first safety factor.

[0068] Step 52: Screen the upper limit of safe temperature to obtain the minimum upper limit of temperature and the corresponding minimum proportion of raw materials.

[0069] The minimum temperature limit refers to the minimum value among the safe temperature limits. It is obtained by comparing and filtering the safe temperature limits to find the minimum value.

[0070] The minimum ratio of raw materials refers to the ratio of raw materials corresponding to the minimum upper temperature limit, which is obtained by finding the ratio of raw materials with the minimum upper temperature limit.

[0071] Step 53: Calculate the minimum temperature difference by subtracting the real-time storage temperature corresponding to the minimum temperature limit and the minimum proportion of raw materials.

[0072] Minimum temperature difference refers to the temperature rise that the minimum proportion of raw materials can withstand under the current storage conditions, which is obtained by subtracting the real-time storage temperature from the minimum upper temperature limit.

[0073] Step 54: If the maximum allowable contact temperature difference is less than the minimum temperature difference, then the maximum allowable contact temperature difference is used as the temperature difference threshold and output.

[0074] If the maximum allowable contact temperature difference is less than the minimum temperature difference, it means that the material itself can withstand a maximum instantaneous temperature difference impact limit that is more stringent than the remaining tolerance space calculated under the current working conditions. The material's own capacity limit must be used as the safety standard, that is, the maximum allowable contact temperature difference is used as the temperature difference threshold and output.

[0075] Step 55: If the maximum allowable contact temperature difference is not less than the minimum temperature difference, then use the minimum temperature difference as the temperature difference threshold and output it.

[0076] If the maximum allowable contact temperature difference is not less than the minimum temperature difference, it means that the material itself has room for the maximum instantaneous temperature difference impact limit. Therefore, the minimum temperature difference is used as the temperature difference threshold and output.

[0077] Step 56: Multiply the minimum temperature limit by the preset second safety factor to obtain the safe preheating limit.

[0078] The second safety factor is a coefficient that further converts the minimum temperature limit into a safe preheating limit. This second safety factor is pre-set by those skilled in the art based on experience and the physical properties of the raw materials.

[0079] The safe preheating limit refers to the highest temperature that can be reached during the preheating stage, which is obtained by multiplying the minimum temperature limit by the second safety factor.

[0080] Step 57: If the hot mixing temperature is less than the safe preheating upper limit, then the hot mixing temperature is used as the preheating temperature and output.

[0081] If the hot mixing temperature is lower than the safe preheating upper limit, it means that the thermal stability of the current raw materials is good enough, and the margin left by the safe preheating upper limit is sufficient. The materials can be directly heated to the hot mixing temperature. Therefore, the hot mixing temperature is used as the preheating temperature and output.

[0082] Step 58: If the hot mixing temperature is not less than the safe preheating upper limit, then use the safe preheating upper limit as the preheating temperature and output it.

[0083] If the hot mixing temperature is not less than the safe preheating upper limit, it means that the safe preheating upper limit is too low and insufficient to support the direct heating of the material to the hot mixing temperature; therefore, the safe preheating upper limit is used as the preheating temperature.

[0084] Reference Figure 2 This includes a method for handling situations where the maximum temperature difference exceeds a temperature difference threshold; this method further includes: Step 70: Combine two adjacent raw materials in the same material category according to the preheating sequence to obtain adjacent raw material groups, and define the raw materials in the adjacent raw material groups as preceding raw materials and subsequent raw materials.

[0085] Adjacent raw material groups refer to combinations of two adjacent raw materials within the same material category, ordered according to their preheating sequence. Adjacent raw material groups are obtained by combining the raw materials corresponding to their preheating sequence in pairs. In an adjacent raw material group, the raw material that appears earlier in the preheating sequence is called the preceding raw material, and the raw material that appears later is called the following raw material.

[0086] Step 71: Calculate the average temperature of adjacent raw material groups by taking the average of their real-time storage temperatures.

[0087] The adjacent average temperature refers to the average of the real-time storage temperatures of two raw materials in adjacent raw material groups. The adjacent average temperature is obtained by adding the real-time storage temperatures of the preceding and following raw materials and dividing by 2.

[0088] Step 72: Stir and heat the two proportioned raw materials in the adjacent raw material groups to the adjacent average temperature to obtain adjacent combined raw materials.

[0089] Adjacent raw material combination refers to a new raw material unit obtained by stirring and heating two raw materials in adjacent raw material groups to adjacent average temperatures. In this step, the stirring and heating of the two raw materials is carried out in a separate preheating unit designed by those skilled in the art, outside of the preheating device. The structure of the preheating unit is the same as that of the preheating device, except that the preheating unit is used for stirring and heating the two raw materials.

[0090] Step 73: Define the adjacent average temperature corresponding to the previous adjacent combination of raw materials as the preceding average temperature, and define the adjacent average temperature corresponding to the next adjacent combination of raw materials as the following average temperature.

[0091] Step 74: According to the preheating sequence, put adjacent combination raw materials into the preheating device in sequence for stirring and heating. When the previous adjacent combination raw material is heated to the average temperature of the subsequent sequence, put the next adjacent combination raw material in, until the next adjacent combination raw material is no longer available. Then stir and heat the proportion of raw materials of the same material category to the preheating temperature.

[0092] The original raw materials are combined in pairs to form new raw material units, and then the new raw material units in the same material category are heated to the preheating temperature step by step according to the preheating sequence.

[0093] Step 75: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

[0094] This also includes: Step 730: Subtract the preceding average temperature from the subsequent average temperature to obtain the adjacent average temperature difference.

[0095] The adjacent average temperature difference refers to the temperature difference between the preceding average temperature and the subsequent average temperature, which is obtained by subtracting the preceding average temperature from the subsequent average temperature.

[0096] Step 731: If the adjacent average temperature difference is greater than the preset adjacent temperature difference threshold, the adjacent average temperature difference that is greater than the preset adjacent temperature difference threshold is defined as the threshold adjacent temperature difference.

[0097] The adjacent temperature difference threshold is a value used to determine whether the temperature difference between adjacent raw materials is too large and whether direct step-by-step heating is possible. The adjacent temperature difference threshold is preset by those skilled in the art based on their process experience.

[0098] If the adjacent average temperature difference is greater than the preset adjacent temperature difference threshold, it means that the temperature difference between adjacent combined raw materials is too large and cannot be directly heated step by step; firstly, the adjacent average temperature difference that exceeds the adjacent temperature difference threshold is defined as the threshold adjacent temperature difference.

[0099] If the average temperature difference between adjacent materials is not greater than the preset threshold for adjacent temperature difference, it means that the temperature difference between adjacent materials is within an acceptable range and can be heated step by step. No additional operation is required at present.

[0100] Step 732: Define the preceding average temperature corresponding to the adjacent temperature difference exceeding the threshold as the preceding temperature exceeding the threshold, and define the subsequent average temperature corresponding to the adjacent temperature difference exceeding the threshold as the subsequent temperature exceeding the threshold.

[0101] Step 733: Combine the preceding raw material corresponding to the preceding temperature above the threshold and the subsequent raw material corresponding to the subsequent temperature above the threshold to obtain the preceding combined raw material group; combine the subsequent raw material corresponding to the preceding temperature above the threshold and the preceding raw material corresponding to the subsequent temperature above the threshold to obtain the subsequent combined raw material group.

[0102] A preceding combination of raw materials refers to a raw material group composed of a cross-pairing of the preceding raw materials corresponding to the original preceding temperature and the subsequent raw materials corresponding to the original subsequent temperature.

[0103] A subsequent batch of raw materials refers to a batch of raw materials formed by cross-pairing the subsequent raw materials corresponding to the original preceding temperature and the preceding raw materials corresponding to the original subsequent temperature.

[0104] The preceding and following combination raw material groups are obtained by breaking down and recombining the preceding and following raw materials corresponding to the original exceeding threshold preceding and following temperatures.

[0105] Step 734: Calculate the preceding combination temperature of the preceding combination raw material group by taking the average of the real-time storage temperatures corresponding to the preceding combination raw material group, and calculate the subsequent combination temperature of the subsequent combination raw material group by taking the average of the real-time storage temperatures corresponding to the subsequent combination raw material group.

[0106] The preceding combination temperature refers to the average of the real-time storage temperatures of the two raw materials in the preceding combination raw material group, which is obtained by adding the real-time storage temperatures of the two raw materials in the preceding combination raw material group and dividing by 2.

[0107] The subsequent combination temperature refers to the average of the real-time storage temperatures of the two raw materials in the subsequent combination raw material group, which is obtained by adding the real-time storage temperatures of the two raw materials in the subsequent combination raw material group and dividing by 2.

[0108] Step 735: Heat the proportioned raw materials in the preceding combination raw material group to the preceding combination temperature and then mix them. Heat the proportioned raw materials in the subsequent combination raw material group to the subsequent combination temperature and then mix them.

[0109] Because the real-time storage temperatures of the recombined raw materials in the preceding and subsequent raw material groups are not the closest, a certain temperature difference will exist during the mixing of the raw materials in the two groups. Therefore, the raw materials in the preceding group need to be heated to the preceding group's temperature before mixing, and the raw materials in the subsequent group need to be heated to the subsequent group's temperature before mixing. This step, mixing the raw materials in the preceding and subsequent groups, is completed in a separate preheating unit, as detailed in step 72.

[0110] Step 736: In adjacent average temperatures, replace the preceding temperature that exceeds the threshold with the preceding combined temperature, and replace the following temperature that exceeds the threshold with the following combined temperature.

[0111] In the original adjacent average temperature, the preceding and subsequent combination temperatures corresponding to the broken and recombined preceding and subsequent combination raw material groups are replaced with the overthreshold preceding and subsequent temperatures of the broken raw material groups to obtain a new adjacent average temperature.

[0112] Step 737: Sort adjacent average temperatures from low to high to obtain the current preheating order of adjacent combinations of raw materials in the same material category.

[0113] The current preheating sequence refers to the preheating order of material discharge obtained by cross-recombining and replacing temperature values, and then reordering them from low to high. The current preheating sequence is obtained by comparing the new adjacent average temperatures obtained within the same material category and sorting them from low to high.

[0114] Step 738: Proceed to step 74 according to the current preheating sequence.

[0115] According to the current preheating sequence, the combined raw materials in the same material category are heated sequentially and placed into the preheating device step by step to be heated to the preheating temperature.

[0116] Step 739: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

[0117] Reference Figure 3 This also includes a method for distributing and heating the preceding and subsequent batches of raw materials, the method comprising: Step 7330: Subtract the previous combination temperature from the subsequent combination temperature to obtain the combined average temperature difference.

[0118] The combined average temperature difference refers to the temperature difference between the preceding and subsequent combined temperatures, which is obtained by subtracting the preceding combined temperature from the subsequent combined temperature.

[0119] Step 7331: If the combined average temperature difference is greater than the preset adjacent temperature difference threshold, then the preceding combined raw material group and the following combined raw material group are disassembled to obtain independent raw materials.

[0120] Independent raw materials refer to materials that have been separated from their preceding and subsequent batches and returned to their original individual state. These independent raw materials no longer participate in the combination process and proceed independently to the subsequent preheating stage.

[0121] If the average temperature difference of the combination is greater than the preset adjacent temperature difference threshold, it means that the temperature difference between the preceding and subsequent raw material groups is too large and cannot be directly heated step by step; it is necessary to disassemble the preceding and subsequent raw material groups to obtain the initial individual materials.

[0122] If the average temperature difference of the combination is not greater than the preset adjacent temperature difference threshold, it means that the temperature difference between the preceding combination of raw materials and the following combination of raw materials is within an acceptable range and can be heated step by step. No additional operation is required at present.

[0123] Step 7332: Sort the adjacent combined raw materials and the independent raw materials in ascending order according to the adjacent average temperature and the real-time storage temperature of the independent raw materials to obtain the mixing order of the adjacent combined raw materials and the independent raw materials.

[0124] The mixing sequence refers to the preheating order in which the remaining adjacent raw materials and independent raw materials are placed together after the cross-combinations are disassembled and recombined, and then discharged again according to their respective temperatures from low to high. The mixing sequence is obtained by comparing the adjacent average temperatures of the remaining adjacent raw materials and the real-time storage temperatures of the independent raw materials, and sorting them in order from low to high.

[0125] Step 7333: According to the mixing order, adjacent combined raw materials and independent raw materials are put into the preheating device in sequence for stirring and heating. The previous adjacent combined raw material or independent raw material is heated to the average temperature of the subsequent sequence or the real-time storage temperature corresponding to the independent raw material, until the next adjacent combined raw material or independent raw material is no longer present. Then, the proportioned raw materials of the same material category are stirred and heated to the preheating temperature.

[0126] Following the mixing sequence, the remaining adjacent combined raw materials and individual raw materials are sequentially placed into the preheating device and stirred and heated step by step to the preheating temperature.

[0127] This also includes an optimization method for the raw material proportioning library, which includes: Step 20: When the safe preheating upper limit is less than the hot mixing temperature, the preheating safety margin is obtained by subtracting the hot mixing temperature from the safe preheating upper limit.

[0128] The preheating safety margin refers to the difference between the hot mixing temperature and the safe preheating upper limit, which is obtained by subtracting the safe preheating upper limit from the hot mixing temperature.

[0129] When the upper limit of safe preheating is less than the hot mixing temperature, it indicates that it is necessary to determine whether the thermal stability of the minimum proportion of raw materials is good enough; calculate the preheating safety margin by subtracting the hot mixing temperature from the upper limit of safe preheating.

[0130] When the upper limit of safe preheating is not less than the hot mixing temperature, it indicates that the thermal stability of the minimum proportion of raw materials is sufficient; no additional operation is required.

[0131] Step 21: If the preheating safety margin is greater than the preset optimization threshold, find alternative raw materials in the raw material ratio library based on the minimum ratio of raw materials.

[0132] The optimization threshold refers to the upper limit of the preheating safety margin, which is preset by those skilled in the art based on experience.

[0133] Substitute ingredients refer to other ingredients in the ingredient ratio library that have the same functional role as the minimum ingredient and can be used interchangeably. Substitute ingredients are found by outputting the minimum ingredient in the ingredient ratio library and searching for ingredients with the same functional role; these substitute ingredients are the ingredients that can be used interchangeably.

[0134] If the preheating safety margin is greater than the preset optimization threshold, it means that the difference between the hot mixing temperature and the upper limit of the safe preheating has exceeded the acceptable range, the thermal stability of the minimum proportion raw material is insufficient, and the temperature that can be reached in the preheating stage is too far from the hot mixing temperature; search for alternative proportion raw materials with the same function but better thermal stability in the raw material proportion library.

[0135] If the preheating safety margin is not greater than the preset optimization threshold, it means that the difference between the hot mixing temperature and the upper limit of safe preheating is within an acceptable range and no additional operation is required.

[0136] Step 22: Based on the alternative raw materials, find the corresponding thermal decomposition temperature of the alternative raw materials in the raw material temperature library.

[0137] The substituted thermal decomposition temperature refers to the thermal decomposition temperature of the substituted raw materials, which can be obtained by searching the raw material temperature database based on the substituted raw materials.

[0138] Step 23: Screen the alternative thermal decomposition temperatures to obtain the highest alternative thermal decomposition temperature, and replace the minimum ratio raw material with the alternative raw material corresponding to the highest alternative thermal decomposition temperature to output the latest required raw material.

[0139] The latest required raw materials refer to the specific raw materials generated after replacing the original minimum ratio raw materials with alternative ratio raw materials. The required raw materials are obtained by sorting out the raw materials after replacing the minimum ratio raw materials with alternative ratio raw materials.

[0140] Step 24: Update the required raw materials for the mixing requirements in the raw material ratio library to the latest required raw materials.

[0141] Update the original required raw materials in the raw material ratio library to the latest required raw materials for easy use later.

[0142] This also includes: Step 210: If no alternative raw material is available, perform a pre-set raw material pretreatment on the minimum raw material to increase the thermal decomposition temperature of the minimum raw material until the preheating safety margin is not greater than the optimization threshold.

[0143] Raw material pretreatment refers to the physical or chemical treatment of raw materials with insufficient thermal stability before they are added to the blend, in order to increase their thermal decomposition temperature. Common methods include: microencapsulating the raw materials with heat-resistant resin, pre-drying the raw materials with auxiliary heat stabilizers under inert gas protection, etc.

[0144] If no alternative raw material is available, it means that the minimum raw material cannot be replaced by finding an alternative raw material. Therefore, the minimum raw material is pretreated, for example, by microencapsulating the material with heat-resistant resin to increase the thermal decomposition temperature of the minimum raw material, until the preheating safety margin calculated based on the increased thermal decomposition temperature is not greater than the optimization threshold.

[0145] Step 211: If a substitute raw material is available, multiply the highest substituted thermal decomposition temperature by the first safety factor to obtain the upper limit of the substituted temperature.

[0146] The upper limit of the surrogate temperature refers to the highest temperature that the surrogate raw materials are allowed to reach during processing. It is obtained by multiplying the highest surrogate thermal decomposition temperature by the first safety factor.

[0147] If a substitute ingredient exists, it means that the minimum ingredient can be replaced by finding a substitute ingredient; at this time, the upper limit of the substitute temperature is calculated.

[0148] Step 212: Define the upper limit of safe temperature for the raw materials in the latest raw material requirements after removing the alternative raw materials as the upper limit of constant temperature.

[0149] The constant temperature upper limit refers to the upper limit of the safe temperature corresponding to the remaining raw materials in the latest required raw materials after removing substitute raw materials. The constant temperature upper limit is determined by first removing substitute raw materials from the latest required raw materials, and the safe upper limit of the remaining raw materials is the constant temperature upper limit.

[0150] Step 213: Filter the replaceable temperature upper limit and the constant temperature upper limit to obtain the current minimum upper limit and the current minimum raw material corresponding to the current minimum upper limit.

[0151] The current minimum upper limit refers to the minimum value between the substitutable temperature upper limit and the constant temperature upper limit, which is obtained by comparing the values ​​of the substitutable temperature upper limit and the constant temperature upper limit and filtering for the minimum value.

[0152] The current minimum raw material refers to the raw material ratio corresponding to the current minimum upper limit, which can be obtained by querying the raw material ratio corresponding to the current minimum upper limit.

[0153] Step 214: Multiply the current minimum upper limit and the second safety factor to obtain the safe preheating upper limit.

[0154] Step 215: When the safe preheating upper limit is still less than the hot mixing temperature, the preheating safety margin is obtained by subtracting the hot mixing temperature from the safe preheating upper limit.

[0155] When the upper limit of safe preheating is still less than the hot mixing temperature, it means that after replacing the minimum proportion of raw materials, it is necessary to determine whether the thermal stability of the current minimum raw materials is good enough; therefore, the preheating safety margin is obtained by subtracting the hot mixing temperature from the upper limit of safe preheating.

[0156] When the upper limit of safe preheating is not less than the hot mixing temperature, it indicates that the thermal stability of the current minimum raw material is sufficient after replacing the minimum proportion raw material; no additional operation is required.

[0157] Step 216: If the preheating safety margin is still greater than the optimization threshold, perform a preset raw material pretreatment on the current minimum raw material to increase the thermal decomposition temperature of the current minimum raw material until the preheating safety margin is no greater than the optimization threshold.

[0158] If the preheating safety margin is still greater than the optimization threshold, it means that the difference between the hot mixing temperature and the upper limit of the safe preheating has exceeded the acceptable range, the thermal stability of the current minimum raw material is insufficient, and the temperature that can be reached in the preheating stage is too far from the hot mixing temperature; therefore, by pre-treating the current minimum raw material, such as microencapsulating the material with heat-resistant resin, the thermal decomposition temperature of the current minimum raw material can be increased until the preheating safety margin calculated based on the increased thermal decomposition temperature is no greater than the optimization threshold.

[0159] If the preheating safety margin is not greater than the optimization threshold, it means that the difference between the hot mixing temperature and the upper limit of the safe preheating is within an acceptable range and no additional operation is required.

[0160] This also includes a method for verifying the weight of raw materials in the formulation, which includes: Step 30: Based on the proportioned raw materials, real-time storage temperature, and hot mixing temperature, find the heating weight change coefficient of the proportioned raw materials from the real-time storage temperature to the hot mixing temperature in the preset temperature and weight database.

[0161] The temperature-weight database contains mapping relationships between the heating weight change coefficients of various raw materials at different proportions, different starting temperatures, and different ending temperatures. The temperature-weight database was established by those skilled in the art based on thermogravimetric analysis data of the raw materials, obtaining the heating weight change coefficients of each raw material at different starting temperatures to different ending temperatures, and using this data.

[0162] The heating weight change coefficient refers to the ratio of weight change of raw materials due to volatilization, decomposition, or other factors when heated from one temperature to another. The heating weight change coefficient can be obtained by inputting the raw materials, initial temperature, and final temperature into a temperature-weight database.

[0163] Step 31: Multiply the weight of each ingredient by the corresponding heating weight change coefficient and sum them to obtain the theoretical finished product weight.

[0164] The theoretical finished product weight refers to the weight that the dry mixture should have after hot mixing, calculated based on the weight of each raw material in the formula and its respective heating weight change coefficient.

[0165] Step 32: Obtain the actual weight of the finished dry mix.

[0166] The actual finished product weight refers to the actual weight of the final dry mix, which is measured by a weighing device configured at the outlet of the hot mixer.

[0167] Step 33: Subtract the theoretical finished product weight from the actual finished product weight to obtain the weight deviation.

[0168] Weight deviation refers to the difference between the theoretical weight of the finished product and the actual weight of the finished product. It is obtained by subtracting the theoretical weight from the actual weight of the finished product and taking the absolute value.

[0169] Step 34: If the weight deviation is greater than the preset weight threshold, output the preset raw material weight abnormality signal.

[0170] The weight threshold refers to the upper limit of allowable weight deviation, which is preset by those skilled in the art based on their process experience.

[0171] The raw material weight anomaly signal is a notification signal indicating that the actual finished product weight is abnormal, facilitating subsequent investigation of the cause of the anomaly. The raw material weight anomaly signal is pre-set by those skilled in the art and is triggered when the weight deviation exceeds a preset weight threshold, providing an audible and visual alert.

[0172] If the weight deviation is greater than the preset weight threshold, it means that the difference between the theoretical finished product weight and the actual finished product weight exceeds the acceptable range; at this time, an abnormal raw material weight signal is output to prompt the operator to investigate the abnormality.

[0173] If the weight deviation is not greater than the preset weight threshold, it means that the difference between the theoretical finished product weight and the actual finished product weight is within an acceptable range; no additional operation is required.

[0174] This also includes a method for monitoring real-time storage temperature, which includes: Step 40: Locate the corresponding normal storage range in the preset storage temperature library according to the proportion of raw materials.

[0175] The storage temperature database contains a mapping relationship between proportioned raw materials and normal storage ranges. Those skilled in the art first set the normal storage range for the proportioned raw materials based on their storage requirements, and then store the proportioned raw materials and their corresponding normal storage ranges in the database to establish the storage temperature database.

[0176] The normal storage range refers to the temperature range within which the raw materials can be stored in a constant-temperature storage tank, which is first set by those skilled in the art based on the storage requirements of the raw materials.

[0177] Step 41: If the real-time storage temperature does not fall within the normal storage range, define the real-time storage temperature that does not fall within the normal storage range as the abnormal storage temperature, and define the raw materials corresponding to the abnormal storage temperature as the abnormal raw materials.

[0178] If the real-time storage temperature does not fall within the normal storage range, it indicates that the real-time storage temperature is abnormal and exceeds the normal storage range. The real-time storage temperature that does not fall within the normal storage range is marked as the abnormal storage temperature, and the raw materials corresponding to the abnormal storage temperature are marked as the abnormal raw materials.

[0179] If the real-time storage temperature falls within the normal storage range, it indicates that the real-time storage temperature is normal, and no additional operations are required.

[0180] Step 42: Find the backup functional raw materials in the raw material ratio library based on the abnormal raw material ratio.

[0181] Backup functional raw materials refer to alternative raw materials in the raw material proportioning library that have the same functional role as the abnormal proportioning raw materials and can be used as replacements. Backup functional raw materials are obtained by searching for proportioning raw materials with the same functional role in the raw material proportioning library based on the abnormal proportioning raw materials.

[0182] Step 43: Update the abnormal ratio raw materials to the backup functional raw materials and output them.

[0183] Replace the abnormally proportioned raw materials with backup functional raw materials for subsequent mixing and use.

[0184] Based on the same inventive concept, embodiments of the present invention provide an intelligent mixing and constant temperature control system for cable protection pipe raw materials.

[0185] A smart mixing and temperature control system for cable protection pipe raw materials includes: The acquisition module is used to acquire information such as raw materials for the protective tube, mixing requirements, real-time storage temperature, and actual finished product weight. The memory stores a computer program that can be loaded and executed by a processor, which is a method for intelligent blending and constant temperature control of raw materials for cable protection pipes. The processor loads and executes programs from memory.

[0186] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0187] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for intelligent mixing and constant temperature control of raw materials for cable protection pipes, characterized in that, include: Step 1: Obtain the raw materials and mixing requirements for the protective tubes stored in each constant temperature storage tank; Step 2: Based on the mixing requirements and the preset raw material ratio library, find the required raw materials, the corresponding raw material weights, the corresponding hot mixing sequence and hot mixing temperature of the required raw materials; Step 3: Weigh the raw materials for the protective tube according to the required raw material weight to obtain the proportioned raw materials; Step 4: Obtain the real-time storage temperature of each proportion of raw materials and calculate the maximum temperature difference between each real-time storage temperature; Step 5: Find the temperature difference threshold and preheating temperature based on the raw material ratio and the preset raw material temperature database; Step 6: If the maximum temperature difference is less than the temperature difference threshold, put the raw materials into the hot mixer in the hot mixing order and stir and heat to the hot mixing temperature to obtain the finished dry mixture. Step 7: If the maximum temperature difference is greater than the temperature difference threshold, classify the raw materials according to the preset raw material database to obtain the material categories, and sort the real-time storage temperature of the same material category from low to high to obtain the preheating order of the raw materials in the same material category. Step 8: According to the preheating sequence, put the proportioned raw materials into the preset preheating device in sequence for stirring and heating. When the previous proportioned raw material is heated to the real-time storage temperature corresponding to the next proportioned raw material, put the next proportioned raw material in, until the next proportioned raw material is no longer available. Then stir and heat the proportioned raw materials of the same material category to the preheating temperature. Step 9: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

2. The intelligent mixing and constant temperature control method for cable protection pipe raw materials according to claim 1, characterized in that, Methods for finding the temperature difference threshold and preheating temperature based on the raw material ratio and a preset raw material temperature database include: Step 50: Find the corresponding thermosensitive data of the raw materials according to the proportioned raw materials and the preset raw material temperature library. The thermosensitive data includes the thermal decomposition temperature and the maximum allowable contact temperature difference. Step 51: Multiply the thermal decomposition temperature of each raw material in the formula with the preset first safety factor to obtain the upper limit of the safe temperature; Step 52: Screen the upper limit of safe temperature to obtain the minimum upper limit of temperature and the corresponding minimum proportion of raw materials; Step 53: Calculate the minimum temperature difference by subtracting the real-time storage temperature corresponding to the minimum temperature limit and the minimum proportion of raw materials; Step 54: If the maximum allowable contact temperature difference is less than the minimum temperature difference, then the maximum allowable contact temperature difference is used as the temperature difference threshold and output. Step 55: If the maximum allowable contact temperature difference is not less than the minimum temperature difference, then use the minimum temperature difference as the temperature difference threshold and output it. Step 56: Multiply the minimum temperature limit by the preset second safety factor to obtain the safe preheating limit; Step 57: If the hot mixing temperature is lower than the safe preheating upper limit, then the hot mixing temperature is used as the preheating temperature and output. Step 58: If the hot mixing temperature is not less than the safe preheating upper limit, then use the safe preheating upper limit as the preheating temperature and output it.

3. The intelligent mixing and constant temperature control method for cable protection pipe raw materials according to claim 2, characterized in that, It also includes a method for handling situations where the maximum temperature difference exceeds a temperature difference threshold, and this method further includes: Step 70: Combine two adjacent raw materials in the same material category according to the preheating sequence to obtain adjacent raw material groups, and define the raw materials in the adjacent raw material groups as preceding raw materials and subsequent raw materials; Step 71: Calculate the average temperature of adjacent raw material groups by taking the average of their real-time storage temperatures. Step 72: Stir and heat the two proportioned raw materials in adjacent raw material groups to the adjacent average temperature to obtain adjacent combined raw materials; Step 73: Define the adjacent average temperature corresponding to the previous adjacent combination of raw materials as the preceding average temperature, and define the adjacent average temperature corresponding to the next adjacent combination of raw materials as the following average temperature. Step 74: According to the preheating sequence, put adjacent combination raw materials into the preheating device in sequence for stirring and heating. When the previous adjacent combination raw material is heated to the average temperature of the subsequent sequence, put the next adjacent combination raw material in, until the next adjacent combination raw material is no longer present. Then stir and heat the proportion of raw materials of the same material category to the preheating temperature. Step 75: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

4. The intelligent mixing and constant temperature control method for cable protection pipe raw materials according to claim 3, characterized in that, Also includes: Step 730: Subtract the preceding average temperature from the subsequent average temperature to obtain the adjacent average temperature difference; Step 731: If the adjacent average temperature difference is greater than the preset adjacent temperature difference threshold, the adjacent average temperature difference that is greater than the preset adjacent temperature difference threshold is defined as the threshold-exceeding adjacent temperature difference. Step 732: Define the preceding average temperature corresponding to the adjacent temperature difference exceeding the threshold as the preceding temperature exceeding the threshold, and define the subsequent average temperature corresponding to the adjacent temperature difference exceeding the threshold as the subsequent temperature exceeding the threshold. Step 733: Combine the preceding raw material corresponding to the preceding temperature above the threshold and the subsequent raw material corresponding to the subsequent temperature above the threshold to obtain the preceding combined raw material group; combine the subsequent raw material corresponding to the preceding temperature above the threshold and the preceding raw material corresponding to the subsequent temperature above the threshold to obtain the subsequent combined raw material group. Step 734: Calculate the preceding combination temperature of the preceding combination raw material group by taking the average of the real-time storage temperatures corresponding to the preceding combination raw material group; calculate the subsequent combination temperature of the subsequent combination raw material group by taking the average of the real-time storage temperatures corresponding to the subsequent combination raw material group. Step 735: Heat the proportioned raw materials in the preceding combination raw material group to the preceding combination temperature and then mix them; heat the proportioned raw materials in the subsequent combination raw material group to the subsequent combination temperature and then mix them. Step 736: In adjacent average temperatures, replace the preceding temperature that exceeds the threshold with the preceding combined temperature, and replace the following temperature that exceeds the threshold with the following combined temperature. Step 737: Sort adjacent average temperatures from low to high to obtain the current preheating order of adjacent combinations of raw materials in the same material category; Step 738: Proceed to step 74 according to the current preheating sequence; Step 739: Add all the raw materials of all major categories into the hot mixer in the hot mixing order, stir and heat to the hot mixing temperature to obtain the finished dry mixture.

5. The intelligent mixing and constant temperature control method for cable protection pipe raw materials according to claim 4, characterized in that, It also includes a method for distributing and heating the preceding and subsequent batches of raw materials, the method comprising: Step 7330: Subtract the previous combination temperature from the subsequent combination temperature to obtain the average temperature difference of the combination; Step 7331: If the combined average temperature difference is greater than the preset adjacent temperature difference threshold, then the preceding combined raw material group and the following combined raw material group are disassembled to obtain independent raw materials. Step 7332: Sort the adjacent combined raw materials and the independent raw materials in ascending order according to the adjacent average temperature and the real-time storage temperature of the independent raw materials to obtain the mixing order of the adjacent combined raw materials and the independent raw materials; Step 7333: According to the mixing order, adjacent combined raw materials and independent raw materials are put into the preheating device in sequence for stirring and heating. The previous adjacent combined raw material or independent raw material is heated to the average temperature of the subsequent sequence or the real-time storage temperature corresponding to the independent raw material, until the next adjacent combined raw material or independent raw material is no longer present. Then, the proportioned raw materials of the same material category are stirred and heated to the preheating temperature.

6. The intelligent mixing and constant temperature control method for cable protection pipe raw materials according to claim 2, characterized in that, It also includes optimization methods for the raw material proportioning library, which include: Step 20: When the safe preheating upper limit is less than the hot mixing temperature, the preheating safety margin is obtained by subtracting the hot mixing temperature from the safe preheating upper limit. Step 21: If the preheating safety margin is greater than the preset optimization threshold, find alternative raw materials in the raw material ratio library based on the minimum ratio of raw materials; Step 22: Based on the alternative raw materials, find the corresponding thermal decomposition temperature of the alternative raw materials in the raw material temperature database; Step 23: Screen the alternative thermal decomposition temperatures to obtain the highest alternative thermal decomposition temperature, and replace the minimum ratio raw material with the alternative raw material corresponding to the highest alternative thermal decomposition temperature to output the latest required raw material. Step 24: Update the required raw materials for the mixing requirements in the raw material ratio library to the latest required raw materials.

7. The intelligent mixing and constant temperature control method for cable protection pipe raw materials according to claim 6, characterized in that, Also includes: Step 210: If no alternative raw material is available, perform a pre-set raw material pretreatment on the minimum raw material to increase the thermal decomposition temperature of the minimum raw material until the preheating safety margin is not greater than the optimization threshold. Step 211: If a substitute raw material is available, multiply the highest substituted thermal decomposition temperature by the first safety factor to obtain the upper limit of the substituted temperature; Step 212: Define the upper limit of safe temperature for the raw materials in the latest demand list after removing the alternative raw materials as the upper limit of constant temperature; Step 213: Filter the upper limit of the substitutable temperature and the upper limit of the constant temperature to obtain the current minimum upper limit and the current minimum raw material corresponding to the current minimum upper limit; Step 214: Multiply the current minimum upper limit and the second safety factor to obtain the safe preheating upper limit; Step 215: When the safe preheating upper limit is still less than the hot mixing temperature, the preheating safety margin is obtained by subtracting the hot mixing temperature from the safe preheating upper limit. Step 216: If the preheating safety margin is still greater than the optimization threshold, perform a preset raw material pretreatment on the current minimum raw material to increase the thermal decomposition temperature of the current minimum raw material until the preheating safety margin is no greater than the optimization threshold.

8. The intelligent mixing and constant temperature control method for cable protection pipe raw materials according to claim 2, characterized in that, It also includes a method for verifying the weight of raw materials in the formulation, the method comprising: Step 30: Based on the proportioned raw materials, real-time storage temperature, and hot mixing temperature, find the heating weight change coefficient of the proportioned raw materials from the real-time storage temperature to the hot mixing temperature in the preset temperature and weight database; Step 31: Multiply the weight of each ingredient by the corresponding heating weight change coefficient and sum them to obtain the theoretical finished product weight; Step 32: Obtain the actual weight of the finished dry mix; Step 33: Subtract the theoretical finished product weight from the actual finished product weight to obtain the weight deviation; Step 34: If the weight deviation is greater than the preset weight threshold, output the preset raw material weight abnormality signal.

9. The intelligent mixing and constant temperature control method for cable protection pipe raw materials according to claim 1, characterized in that, It also includes a method for monitoring real-time storage temperature, which includes: Step 40: Locate the corresponding normal storage range in the preset storage temperature warehouse according to the proportion of raw materials; Step 41: If the real-time storage temperature does not fall within the normal storage range, define the real-time storage temperature that does not fall within the normal storage range as the abnormal storage temperature, and define the raw materials corresponding to the abnormal storage temperature as the abnormal raw materials. Step 42: Based on the abnormal ratio of raw materials, find the alternative functional raw materials in the raw material ratio library; Step 43: Update the abnormal ratio raw materials to the backup functional raw materials and output them.

10. A smart mixing and constant temperature control system for cable protection pipe raw materials, characterized in that, include: The acquisition module is used to acquire information such as raw materials for the protective tube, mixing requirements, real-time storage temperature, and actual finished product weight. A memory for storing a program for a method of intelligent mixing and constant temperature control of raw materials for cable protection pipes as described in any one of claims 1 to 9; The processor loads and executes programs from memory.

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