Extrusion molding apparatus with dual requirements, operation health assessment method and system

Abstract

Provided are an extrusion molding device with dual requirements, an operation health degree evaluation method and system, the extrusion molding device comprising an extrusion molding host, a control system and a simulation practical training module, the control system being configured with a permission system for two scenarios, so that production and operation permissions correspond to production modes and teaching and practical training permissions correspond to practical training modes, the simulation practical training module providing a simulation operation environment for the whole process of extrusion molding, the two permissions not being interconnected, thus realizing the combination of theoretical teaching and real production conditions.The extrusion molding device operation health degree evaluation method makes the production evaluation of the extrusion molding device accurate and reasonable by reasonably setting the evaluation weight proportions of each subunit.

Description

Technical Field

[0001] This invention relates to the field of molding apparatus for materials in a plastic state, and more specifically to the field of extrusion molding apparatus. Background Technology

[0002] Extrusion molding is a core molding process in industries such as plastics, rubber, and food processing. The stable and healthy operation of extrusion molding equipment directly determines production efficiency, product quality, and production safety.

[0003] The existing system lacks an adaptation design for teaching scenarios, cannot meet the dual needs of equipment operation and maintenance and practical training, and also lacks a detection system and method that can effectively detect and intuitively evaluate the operational health of the extrusion molding device. Summary of the Invention

[0004] One objective of this invention is to provide an extrusion molding apparatus with dual requirements, capable of simultaneously meeting the needs of production operation and maintenance as well as teaching and training.

[0005] To achieve the above objectives, the extrusion molding apparatus includes an extrusion molding host, a control system, and a simulation training module. The extrusion molding host is used to perform material extrusion production. The control system is signal-connected to the extrusion molding host and includes a permission management module. This module divides operation permissions into production operation and maintenance permissions and teaching and training permissions. The production operation and maintenance permissions correspond to the production mode, and the teaching and training permissions correspond to the training mode. The simulation training module provides a virtualized operating environment. This module is configured to provide a simulated operating environment for the entire extrusion molding process. Operation commands in the simulated operating environment are not transmitted to the extrusion molding host. The control system is configured to allow the production mode and the training mode to run simultaneously or selectively.

[0006] Another objective of this invention is to provide a method for evaluating the operational health of an extrusion molding apparatus. This method includes the following steps: S1. Dividing the extrusion molding apparatus into multiple sub-units, setting independent evaluation criteria for each sub-unit, and assigning independent evaluation weight ratios to each sub-unit; S2. Running the extrusion molding apparatus and collecting the operating parameters of each sub-unit in real time; S3. Calculating the health score of the operating parameters of each sub-unit based on the evaluation criteria, and obtaining a real-time score for each sub-unit based on the evaluation weight ratio and the health score; S4. Using the real-time score to determine the operational health of the extrusion molding apparatus.

[0007] In one or more embodiments, the extrusion molding apparatus includes a main drive unit, a gearbox and load-bearing component unit, a temperature control unit, a melt process unit, an actuator unit, and an operation and maintenance and safety unit, such that the sum of the evaluation weight ratios of the main drive unit, gearbox and load-bearing component unit, temperature control unit, melt process unit, actuator unit, and operation and maintenance and safety unit is kept at 100%.

[0008] In one or more embodiments, the evaluation weight ratio of the gearbox and carrier component unit is proportional to its statistical probability of failure; and / or the evaluation weight ratio of the temperature control unit is proportional to its statistical probability of failure; and / or the evaluation weight ratio of the melt process unit is proportional to its statistical probability of failure; and / or the evaluation weight ratio of the actuator unit is proportional to its statistical probability of failure.

[0009] In one or more embodiments, the evaluation weight ratios of the main drive unit, the gearbox and load-bearing component unit, the temperature control unit, the melt process unit, the actuator unit, and the operation and maintenance and safety unit are decreased sequentially.

[0010] In one or more embodiments, the evaluation weighting of the temperature control unit is increased based on the thermal sensitivity of the material; and / or the evaluation weighting of the melt process unit is increased based on the product quality accuracy value.

[0011] In one or more embodiments, the material is polypropylene or polycarbonate, which gives the host drive unit the highest evaluation weight and the gearbox and load-bearing component unit the second highest evaluation weight; or the material is polyvinyl chloride, which gives the temperature control unit the highest evaluation weight and the melt process unit the second highest evaluation weight.

[0012] In one or more embodiments, the weight allocation range of the main drive unit is 20% to 30%, the weight allocation range of the gearbox and load-bearing component unit is 15% to 25%, the weight allocation range of the temperature control unit is 15% to 25%, the weight allocation range of the melt process unit is 10% to 20%, the weight allocation range of the actuator unit is 5% to 15%, and the weight allocation range of the operation and maintenance and safety unit is 5% to 15%.

[0013] In one or more embodiments, each subunit includes a normal operation range, a warning range, a fault range, and a severe fault range. The health of each subunit is determined using its real-time score, including the following steps: if the real-time score is not in the warning range, the subunit is determined to be in the normal operation range; if the real-time score is in the warning range but has not reached a fault threshold, the subunit is determined to be in the warning range; if the real-time score exceeds the fault threshold, but the core operating parameters of the subunit are within the normal range, the subunit is determined to be in the fault range; if the core operating parameters of the subunit exceed a safety threshold, the subunit is determined to be in the severe fault range.

[0014] In one or more embodiments, the operational health score is 100 points. The evaluation method further includes degradation rules, which include a first-level degradation rule and a second-level degradation rule. When the first-level degradation rule is met, the operational health score of the extrusion molding device is reduced to 60 points. When the second-level degradation rule is met, the operational health score of the extrusion molding device is reduced to 0 points. The first-level degradation rule includes one of the following: at least three sub-units are simultaneously in the warning interval, and any one sub-unit is in the severe fault interval. The second-level degradation rule includes one of the following: the operation and maintenance and safety unit is in the severe fault interval, and the main drive unit is in the severe fault interval. When both the first-level degradation rule and the second-level degradation rule are met, the second-level degradation rule is executed.

[0015] Another object of the present invention is to provide a health assessment system for an extrusion molding apparatus, used in the above-described method. The system includes a parameter acquisition unit, a main control processing unit, and a safety interlock unit. The parameter acquisition unit includes multiple sub-unit parameter acquisition components. The main control processing unit is signal-connected to the parameter acquisition unit and includes a health status quantification scoring module. The health status quantification scoring module is used to calculate and output a health score and / or health level based on the data acquired by the sub-unit parameter acquisition components. The safety interlock unit is signal-connected to the main control processing unit and is used to perform a shutdown operation based on the health score and / or health level.

[0016] In one or more embodiments, the system further includes a human-computer interaction unit, which includes a parameter configuration module and a data visualization module. The parameter configuration module is used to input thresholds and evaluation weight ratios, and the data visualization module is used to display the operating parameters, health scores, and warning information of each subunit.

[0017] The extrusion molding device described above combines theoretical teaching with real production conditions by configuring a permission system for two scenarios, so that production and maintenance permissions correspond to production mode and teaching and training permissions correspond to training mode. The two permissions are not interconnected. Attached Figure Description

[0018] The above and other features, properties and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings and embodiments, wherein: Figure 1 This is a schematic diagram of the structure of the extrusion molding machine; Figure 2 This is a schematic diagram of the execution logic of an extrusion molding device with dual requirements; Figure 3 This is a flowchart of the method for assessing the operational health of an extrusion molding unit; Figure 4 This is a cross-sectional view of the extrusion molding machine; Figure 5 This is a schematic diagram of the sub-unit distribution; Figure 6 This is a schematic diagram of the health assessment system for extrusion molding equipment. Detailed Implementation

[0019] The present invention will be further described below with reference to specific embodiments and accompanying drawings. More details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention can obviously be implemented in many other ways different from those described herein. Those skilled in the art can make similar extensions and derivations based on actual application situations without departing from the spirit of the present invention. Therefore, the scope of protection of the present invention should not be limited by the content of this specific embodiment.

[0020] It should be noted that these and other accompanying drawings are merely examples and are not drawn to scale, and should not be construed as limiting the scope of protection of the present invention.

[0021] Extrusion molding mainly includes four processes: feeding, plasticizing, molding, and setting. (See reference...) Figure 1 The extrusion molding machine 100 shown illustrates the process where granular or powdered thermoplastic is first added to the hopper 11. Under the action of the rotating screw 12, the heated plastic is conveyed forward F along the spiral groove of the screw. During this process, the plastic continuously receives heat and gradually melts into a viscous flow state. Under the action of the extrusion system 13, the molten plastic passes through a die head 14 with a certain shape and a series of auxiliary tools, outputting a plastic profile with a certain cross-sectional shape. The auxiliary tools include, but are not limited to, shaping, cooling, traction, and cutting devices.

[0022] This extrusion molding device with dual requirements, such as Figure 2 As shown, it includes the above-mentioned extrusion molding host for performing material extrusion production, and also includes a control system 200 and a simulation training module 300.

[0023] The control system 200 is connected to the extrusion molding host 100 by signal. The control system includes an access control module, which is used to divide the operation permissions into production operation and maintenance permissions and teaching and training permissions. The production operation and maintenance permissions correspond to the production mode 210, and the teaching and training permissions correspond to the training mode 220.

[0024] The simulation training module 300 can be integrated into the control system 200 to provide a virtualized operating environment, including a human-machine interface. The simulation training module 300 is configured to provide a simulated operating environment for the entire extrusion molding process. In the simulated operating environment, operating instructions are not transmitted to the extrusion molding host 100, and operators have only read-only access.

[0025] The control system is configured to allow production mode and training mode to operate in parallel or selectively.

[0026] When running in parallel, both training mode 220 and production mode 210 are enabled. One system can run "production mode" and "training mode" at the same time. The actual production process does not affect the students' simulated training operations on the simulated training module 300, and the training operations will not have any impact on the operation of the real equipment.

[0027] When conducting independent training mode 220, only read-only access to the data of the real equipment is granted, completely isolating the control permissions of the real equipment. Learners can complete the entire process of operation practice without any equipment risk, and can also view the operating data of the real equipment, thus combining theoretical teaching with real working conditions.

[0028] When operating in independent production mode 210, all control, monitoring, and configuration permissions for real equipment are granted to meet core needs such as equipment start-up and shutdown, status monitoring, health assessment, fault warning, and emergency braking during the production process.

[0029] Extrusion molding equipment requires real-time monitoring of the production process in order to conduct real-time assessment of equipment health status and anticipate potential failures.

[0030] Based on this, this disclosure also proposes a method for assessing the operational health of an extrusion molding apparatus, which is applicable not only to the aforementioned extrusion molding apparatus with dual requirements, but also to extrusion molding apparatuses of all sizes in a factory.

[0031] Reference Figure 3 The method, as understood, includes the following steps.

[0032] S1. Divide the extrusion molding device into multiple sub-units, set independent evaluation criteria for each sub-unit, and assign independent evaluation weight ratios to each sub-unit.

[0033] S2. Operate the extrusion molding device and collect the operating parameters of each sub-unit in real time.

[0034] S3. Calculate the health score of the operating parameters of each sub-unit according to the evaluation criteria, and obtain the real-time score of each sub-unit based on the evaluation weight ratio and health score of each sub-unit.

[0035] S4. Use real-time scoring to determine the operational health of the extrusion molding unit.

[0036] It can also continue to match health levels based on operational health and output operation and maintenance suggestions based on health levels. When the health level is poor, the security interlock linkage function will be activated. This part will be described in detail below.

[0037] Specifically, in one particular embodiment, such as Figure 4 and Figure 5 As shown, the extrusion molding apparatus is divided into six units: main drive unit 101, gearbox and load-bearing component unit 102, temperature control unit 103, melt process unit 104, actuator unit 105, and operation and maintenance and safety unit 106.

[0038] The main drive unit 101 includes components such as a motor 15, a cycloidal pinwheel reducer 16, and a coupling 17.

[0039] The gearbox and load-bearing component unit 102 includes components such as gearbox 18 and thrust bearing housing 19.

[0040] The temperature control unit 103 includes components such as barrel temperature sensor 22, mold temperature sensor 20, and melt temperature sensor 21.

[0041] The melt process unit 104 includes components such as the die head pressure sensor 23 and the mold pressure sensor 24.

[0042] The actuator unit 105 includes components such as a clamp locking device 25, a hopper 11, and a support 26.

[0043] The maintenance and safety unit 106 includes components such as a torque sensor 27 and a safety coupling 28. The safety coupling 28 can be directly disconnected when necessary. The torque sensor 27 issues an alarm signal when the torque value exceeds a threshold.

[0044] Each subunit performs a different function, and therefore has its own independent evaluation criteria and weighting. The evaluation criteria for each subunit are explained below.

[0045] The main drive unit 101 is the core transmission system. Its core evaluation targets are the safety, stability, and matching degree of power output, requiring a focus on assessing the operational reliability of the equipment's power core. The core evaluation parameters for the main drive unit 101 include speed matching degree, current load rationality, torque stability, and start-stop compliance, corresponding to the core characteristics of power output accuracy, load safety, operational stability, and operational compliance, respectively. The closer the parameters are to the rated optimal range, the smaller the fluctuation range, and the more reasonable the load, the higher the evaluation score; conversely, the greater the deviation, the greater the fluctuation, and the more extreme the load, the lower the evaluation score.

[0046] For example, in one specific embodiment, for the main drive unit, the full score for the main drive unit speed matching is 6 points: 6 points for a deviation of ≤1% between the speed setpoint and the feedback value; 3 points for 1% < deviation ≤3%; 1 point for 3% < deviation ≤5%; and 0 points for a deviation >5%. The full score for the motor current load matching is 6 points: 6 points for a current load rate of 20%-80%; 3 points for 10%-20% or 80%-90%; 1 point for 5%-10% or 90%-100%; and 0 points for <5% or >100%. The full score for the main drive unit torque stability is 7 points: 7 points for torque load of 30%-70% with fluctuation ≤5%; 4 points for 20%-30% or 70%-85% with fluctuation 5%-10%; 1 point for 10%-20% or 85%-100% with fluctuation 10%-15%; and 0 points for <10% or exceeding the rated value with fluctuation >15%. The full score for the compliance of the power-on self-test and start-stop function is 6 points: 6 points are awarded for passing all self-tests, normal start-stop, and no-load current ≤ 5% of the rated value; 3 points are awarded for one non-core self-test abnormality; 0 points are awarded for core self-test abnormality or start-stop failure.

[0047] The gearbox and load-bearing component unit 102 is evaluated based on wear warning and lifespan. Therefore, the core evaluation targets are the wear state and remaining service life of the components, and the evaluation can reflect the degradation trend of the components. Based on the component's design life threshold and factory rating, the core evaluation parameters include temperature, vibration, load, oil wear, and structural tightness, corresponding to common failure modes such as component overheating, fatigue wear, overload, lubrication failure, and structural loosening, respectively. The further the parameters are from the wear warning threshold, the lower the metal ion content, and the better the structural tightness, the higher the evaluation score; conversely, the closer the temperature and vibration are to the warning threshold, and the higher the wear degree, the lower the evaluation score. Even if the parameters do not exceed the threshold, if they continue to rise and the wear trend is obvious, points will be deducted accordingly to achieve early warning.

[0048] In one specific embodiment, the scoring rules for the gearbox and load-bearing component units are as follows: The maximum score for core temperature parameters is 6 points: 6 points are awarded if both gearbox temperature and bearing temperature are ≤80% of the rated temperature and the temperature difference with the environment is ≤40℃; 3 points are awarded if either reaches 80%-90%; 1 point is awarded if it reaches 90%-100%; 0 points are awarded if it exceeds the rated value or alarm value. The maximum score for vibration and load parameters is 6 points: 6 points are awarded if vibration value ≤60% of the warning value and thrust ≤70% of the warning value; 3 points are awarded if vibration is 60%-80% or thrust is 70%-90%; 1 point is awarded if vibration is 80%-100% or thrust is 90%-100%; 0 points are awarded if it exceeds the warning value. The maximum score for oil wear parameters is 4 points: 4 points are awarded if metal ion content is ≤30% of the threshold; 2 points are awarded if 30%-70%; 1 point is awarded if 70%-100%; 0 points are awarded if it exceeds the threshold. The maximum score for structural fastening parameters is 4 points: 4 points are awarded if the torque of the gearbox clamp is within ±5% of the set value on both sides and the difference between the two ends is ≤10%; 2 points are awarded if the deviation of one end is 5%-10%; 1 point is awarded if the deviation is 10%-15%; and 0 points are awarded if the deviation exceeds ±15% or the difference is >20%.

[0049] The temperature control unit 103 focuses on the accuracy and stability of temperature control as its core evaluation objectives, assessing the stability of the temperature field that plays a decisive role in the plasticizing quality of materials. Using the process setpoint as the core benchmark, rather than the equipment's rated value, it prioritizes evaluating the deviation and fluctuation range of temperature from the setpoint to adapt to the processing requirements of different materials. The core evaluation dimensions are the temperature control accuracy of the barrel zone, the temperature control accuracy of the mold zone, and the temperature stability of the cooling system, corresponding to the temperature control effects of the three core process stages of material plasticizing, molding, and cooling, respectively. Smaller deviations and smaller fluctuation ranges result in higher scores; larger deviations and more drastic fluctuations result in lower scores. Single-zone temperature differences only deduct the corresponding score; simultaneous deviations in multiple zones trigger a mandatory downgrade rule.

[0050] In a specific embodiment of the temperature control unit evaluation, the full score for the barrel zone temperature control accuracy is 8 points: 8 points are awarded if the temperature deviation of each of the barrel zones 1-3 from the set value is ≤ ±2℃; 5 points are awarded if the deviation of one zone is 2-5℃; 2 points are awarded if the deviation of two zones is 2-5℃; and 0 points are awarded if the deviation of any zone is > 5℃ or an alarm sounds. The full score for the mold zone temperature control accuracy is also 8 points: 8 points are awarded if the temperature deviation of each of the mold zones 1-3 from the set value is ≤ ±2℃; 5 points are awarded if the deviation of one zone is 2-5℃; 2 points are awarded if the deviation of two zones is 2-5℃; and 0 points are awarded if the deviation of any zone is > 5℃ or an alarm sounds. The full score for the cooling system temperature stability is 4 points: 4 points are awarded if the deviation of each cooling water temperature from the set value is ≤ ±3℃ and the fluctuation is ≤ 2℃; 2 points are awarded if the deviation of one cooling water line is 3-5℃; 1 point is awarded if the deviation of two or more cooling water lines is 3-5℃; and 0 points are awarded if the deviation of any cooling water line is > 5℃.

[0051] Melt process unit 104 prioritizes molding quality and stability, with melt state stability as the core evaluation objective. This directly impacts the final extruded product's molding quality, focusing on the consistency of core process parameters. The core benchmark is the process setpoint, with the core evaluation dimensions being "melt pressure stability, melt temperature uniformity, and flow rate stability." These three parameters directly determine the melt's rheological state and are key factors influencing product quality. Smaller deviations and fluctuations between parameters and setpoints indicate a more stable melt state and a higher score; larger deviations and more drastic fluctuations increase the probability of product defects and result in a lower score. Parameters in this module directly affect product quality; any sub-item triggering a fault threshold will trigger load limits, with exceeding the threshold by 120% triggering an emergency shutdown.

[0052] In a specific embodiment of the melt process unit, the maximum score for melt pressure stability is 6 points: 6 points for deviation ≤ ±3% and fluctuation ≤ 2% from the set value; 3 points for deviation 3%-5% and fluctuation 2%-5%; 1 point for deviation 5%-8% and fluctuation 5%-10%; 0 points for deviation > 8% or alarm. The maximum score for melt temperature uniformity is 5 points: 5 points for deviation ≤ ±3℃ from the set value; 2 points for 3-6℃; 1 point for 6-10℃; 0 points for >10℃ or alarm. The maximum score for flow rate stability is 4 points: 4 points for deviation ≤ ±5% from the set value for each flow path of the screw, barrel, and die; 2 points for a deviation of 5%-10% for one path; 1 point for a deviation of 5%-10% for two or more paths; 0 points for any deviation > 10%.

[0053] Actuator unit 105 requires precision and safety compliance. The core evaluation objectives are the precision and operational safety of the actuator, with a focus on assessing the reliability and compliance of the auxiliary mechanism. Based on the mechanism's design specifications and motion settings, the core evaluation dimensions are "servo system operational precision" and "clamp system operational status," corresponding to the positioning precision of the moving mechanism and the tightness and safety of the opening and closing mechanism, respectively. The smaller the positional deviation, the closer the torque is to the reasonable range, and the normal the motion, the higher the evaluation score; conversely, the larger the positional deviation and the closer the torque is to the limit, the lower the evaluation score. This module is an auxiliary system; a single sub-item failure only deducts the corresponding points and does not trigger a forced downgrade. However, if the mechanism malfunctions or the torque exceeds the limit, a safety shutdown will be triggered directly.

[0054] In a specific embodiment of the actuator unit evaluation system, the full score for the operational accuracy of the mobile servo system is 4 points: 4 points for position deviation ≤ 0.1mm and torque ≤ 80% of the limit; 2 points for 0.1-0.3mm or torque 80%-100%; 1 point for 0.3-0.5mm; and 0 points for > 0.5mm or exceeding the limit. The full score for the operating status of the clamp system is 6 points: 6 points for left and right clamp torque within the limit, difference ≤ 10%, and normal operation; 3 points for single-end torque reaching 80%-100%; 1 point for difference 10%-20%; and 0 points for exceeding the limit or operational failure.

[0055] The Operations and Safety Unit 106 prioritizes bottom-line control and effective interlocking, with equipment safety bottom-line control as the core evaluation objective. It focuses on assessing the effectiveness of safety interlocking functions and the compliance of operations and maintenance, serving as the last line of defense for equipment safety. Using safe operating procedures and equipment operation and maintenance specifications as absolute benchmarks, the core evaluation dimensions are "safety interlocking and alarm functions, operation and maintenance compliance, and shutdown and standby management." Higher scores are awarded for intact safety interlocking functions, no unauthorized alarm blocking, and compliant operation and maintenance. Blocking non-core alarms deducts corresponding points; failure of core interlocking or unauthorized blocking of core alarms directly triggers a zero-score rule. This module represents the safety bottom line and employs a "one-vote veto" system. When the zero-score rule is triggered, regardless of the scores of other modules, the final score is directly reduced to zero, and an emergency shutdown is executed.

[0056] For the Operations and Security unit, including security interlocking and alarm functions, operations and maintenance compliance, and shutdown and standby management, the maximum score for security interlocking and alarm functions is 4 points: 4 points for normal interlocking, intact alarms, and no unauthorized blocking; 2 points for blocking non-core alarms; 0 points for core interlocking failure. The maximum score for operations and maintenance compliance is 4 points: 4 points for gear oil usage time within the set value and complete records; 2 points for exceeding the set value by less than 10%; 0 points for exceeding 10%. The maximum score for shutdown and standby management is 2 points: 2 points for shutdown in accordance with procedures and no abnormalities in standby; 1 point for minor abnormalities in standby; 0 points for shutdown exceeding the time limit without maintenance.

[0057] The evaluation weighting of each sub-unit varies due to factors such as its functional importance, different failure probabilities, and the physical and chemical properties of the materials. The evaluation weighting of each sub-unit is explained below.

[0058] The more critical the function of a sub-unit, the greater its impact on equipment safety, personal safety, and production continuity after a failure, and therefore the higher its weight. The main drive system is the power core of the equipment; a failure in this system directly leads to equipment shutdown and may even cause irreversible damage such as motor burnout and screw breakage. The severity of such failures is high, therefore, in principle, it should have a higher weight. Similarly, the core process parameters of the melt directly determine the molding quality of the extruded product and are the core objective of production and experimentation; therefore, their weight allocation should not be too low.

[0059] In one embodiment, the evaluation weights of the main drive unit, gearbox and load-bearing component unit, temperature control unit, melt process unit, actuator unit, and operation and safety unit are decreased sequentially. When the total health assessment score is 100 points, the evaluation weights of the main drive unit, gearbox and load-bearing component unit, temperature control unit, melt process unit, actuator unit, and operation and safety unit are 25%, 20%, 20%, 15%, 10%, and 10% respectively, which means the maximum scores for each sub-unit are 25, 20, 20, 15, 10, and 10 points respectively.

[0060] The statistical probability of failure occurrence is also an important basis for weight allocation.

[0061] The evaluation weights of the gearbox and load-bearing component units should be proportional to their failure probability; and / or

[0062] The evaluation weighting of the temperature control unit should be proportional to its statistical probability of failure; and / or

[0063] The evaluation weighting of the melt process unit should be proportional to its statistical probability of failure; and / or

[0064] The evaluation weight ratio of the actuator unit is proportional to its statistical probability of failure.

[0065] In some embodiments, the statistical probability of failure refers to the proportion of the number of failures of each unit or component in the host within a year to the total number of failures.

[0066] According to statistics on extrusion unit failure cases, the failure probability of temperature control unit, gearbox and load-bearing component unit is 32% and 28% respectively, which are the most common sources of equipment failure. Therefore, the weights can be adjusted to increase the scores of temperature control unit, gearbox and load-bearing component unit to 23 and 22 respectively, while decreasing the score of main drive unit to 20.

[0067] Furthermore, the physicochemical properties of materials directly affect the weight allocation. The following three examples illustrate the physicochemical properties of materials and the weight allocation.

[0068] In the first embodiment, when the material is polypropylene (PP), the material has the physical and chemical properties of low melt viscosity, wide processing temperature window (180-280℃), good thermal stability, and insensitivity to shear and temperature fluctuations. It is the most commonly used general plastic for extrusion molding, with a high processing tolerance. The core risk point is the long-term wear of the equipment power system and load-bearing components.

[0069] Based on this, in this embodiment, the evaluation weight ratios of the main drive unit, gearbox and load-bearing component unit, temperature control unit, melt process unit, actuator unit, and operation and maintenance and safety unit are adjusted to 30%, 25%, 15%, 15%, 10%, and 5%, respectively.

[0070] PP processing demands high equipment power stability. In long-term continuous production scenarios, failures in the main drive system are the core cause of production interruptions; therefore, the importance of strengthening the health monitoring of the power system should be increased. PP extrusion is typically a continuous production process, with gearboxes and screws under constant load. Wear is the primary mode of equipment failure, so the importance of early warning systems for component lifespan should be increased. PP processing has a wide temperature window, and slight temperature fluctuations do not affect processing quality; therefore, the importance of temperature control units can be reduced. In continuous production scenarios, maintenance standards are high; therefore, the importance of maintenance and safety interlock units should be reduced, focusing instead on monitoring core equipment components.

[0071] In the second embodiment, the material is polycarbonate (PC). As a high-viscosity engineering plastic, polycarbonate has extremely high melt viscosity, high processing temperature (280-320℃), sensitivity to shear rate, and extremely high requirements for temperature uniformity, making it difficult to process. The core risks are melt plasticization uniformity, safety of the main machine under high load, and mold forming temperature control.

[0072] Based on this characteristic, in this embodiment, the evaluation weight ratios of the main drive unit, gearbox and load-bearing component unit, temperature control unit, melt process unit, actuator unit, and operation and maintenance and safety unit are adjusted to 28%, 22%, 20%, 15%, 5%, and 10%, respectively.

[0073] Because of the high viscosity of PC, the main unit operates under high load for extended periods. Motor torque and current overload are core safety risks, necessitating an increased weighting of the main unit's transmission unit and enhanced health monitoring during high-load operation. PC processing screws experience high axial thrust, placing high loads on gearboxes and bearings; therefore, the weighting of gearbox and load-bearing component units must be increased, along with enhanced overload warning systems for these components. Uniform barrel and mold temperature is crucial for PC plasticization, requiring a high weighting for the temperature control unit. Melt pressure and viscosity are key indicators of plasticization quality, necessitating a maintained weighting for the core melt unit. PC processing has low precision requirements for actuators, allowing for a reduction in the weighting of actuators and auxiliary systems.

[0074] In the third embodiment, the material is polyvinyl chloride (PVC). Polyvinyl chloride (PVC) is a heat-sensitive plastic. Its core physicochemical properties are extremely poor thermal stability, a very narrow processing temperature window (160-180℃), and rapid thermal degradation at temperatures exceeding 190℃, releasing hydrogen chloride that corrodes equipment. It is also highly sensitive to shear rate, with extremely low processing tolerance. The core risks are the accuracy of temperature control and the stability of the melt state.

[0075] Based on this, in this embodiment, the evaluation weight ratios of the main drive unit, gearbox and load-bearing component unit, temperature control unit, melt process unit, actuator unit, and operation and maintenance and safety unit are adjusted to 20%, 15%, 25%, 20%, 10%, and 10%, respectively.

[0076] In this embodiment, the core drive system of the main unit retains its core weight but is slightly reduced, primarily focusing on risk management of the processing technology. PVC processing is typically done in small to medium batches, with low risk of component wear; therefore, the weight of the gearbox and key load-bearing components is reduced. PVC is extremely heat-sensitive, and the accuracy of temperature control directly determines whether the material degrades and whether the product is qualified, making it a core risk point in processing; therefore, the weight of the temperature control unit needs to be significantly increased. Melt temperature and pressure directly reflect the degradation risk of the material and the molding quality; therefore, the weight of the melt core unit is significantly increased, and melt state monitoring is strengthened.

[0077] To meet the needs of different extrusion unit models and application scenarios, the weights of each subunit are adjustable. The weight allocation range for the main drive unit 101 is 20%~30%, for the gearbox and load-bearing component unit 102 it is 15%~25%, for the temperature control unit 103 it is 15%~25%, for the melt process unit 104 it is 10%~20%, for the actuator unit 105 it is 5%~15%, and for the operation and maintenance and safety unit 106 it is 5%~15%.

[0078] That is, the maximum score for the main drive unit 101 is 20-30 points, the maximum score for the gearbox and load-bearing component unit 102 is 15-25 points, the maximum score for the temperature control unit 103 is 15-25 points, the maximum score for the melt process unit 104 is 10-20 points, the maximum score for the actuator unit 105 is 5-15 points, and the maximum score for the operation and maintenance and safety unit 106 is 5-15 points.

[0079] In most embodiments, the weight allocation value of the host drive unit 101 is maximized.

[0080] The above-mentioned weighting ratios make the production evaluation of extrusion molding equipment more accurate and reasonable.

[0081] After determining the evaluation weight ratios, the extrusion molding unit is operated, and the operating parameters of each subunit are collected in real time using the parameter acquisition unit. The parameter acquisition unit includes parameter acquisition components located on each subunit, which will be described in detail below.

[0082] The health score of the operating parameters of each sub-unit is calculated according to the evaluation criteria. Based on the evaluation weight ratio and health score of each sub-unit, the real-time score of each sub-unit is obtained, and the sum of the real-time scores is used to determine the operating health of the extrusion molding device.

[0083] In some embodiments, based on the real-time scores of each subunit, each subunit is defined with a normal operation range, a warning range, a fault range, and a severe fault range. Each subunit follows the same judgment logic.

[0084] When the real-time score of a subunit is not in the warning range, the subunit is determined to be in the normal operating range.

[0085] When the real-time score is in the warning range but has not reached the fault threshold, the subunit is determined to be in the warning range.

[0086] When the real-time score exceeds the fault threshold, but the core operating parameters of the subunit are within the normal range, the subunit is judged to be in a fault range. Specifically, in some embodiments, the core operating parameters of the main drive unit 101 are torque and main unit current, with a threshold of 100% of the maximum allowable value. The core parameters of the gearbox and load-bearing component unit 102 are temperature and vibration values. The temperature threshold varies depending on the processed material, including but not limited to 85℃ and 95℃. The vibration threshold is 0.5mm. The core parameter of the temperature control unit 103 is the deviation between the temperature and the set value, with a threshold range generally ±10℃. The core parameters of the melt process unit 104 are melt pressure and melt temperature, which vary depending on the material characteristics. The melt pressure is generally 15-25MPa; the melt temperature is 8.5~11.5℃ below the material degradation temperature. The core parameter of the actuator unit 105 is the positioning progress of the moving mechanism and opening / closing mechanism, with a threshold deviation of 0.3mm. The core parameter of the operation and safety unit 106 is the torque detection value, with a threshold range of 80% of the maximum allowable torque value.

[0087] When the core operating parameters of a subunit exceed the safety threshold, the subunit is identified as being in a critical fault range.

[0088] Each interval has a corresponding feedback mechanism.

[0089] If the system is operating normally, a green indicator will be displayed on the human-computer interaction interface.

[0090] If the system is in the warning zone, a yellow warning message will pop up on the human-machine interface, indicating the abnormal parameters, the cause of the abnormality, and handling suggestions; the system will output a low-frequency audible and visual warning signal to remind operators to pay attention; the system will not restrict the operation of the equipment, will not perform a shutdown operation, and the equipment can operate normally; the warning event will be recorded simultaneously to the data storage module for subsequent traceability.

[0091] If the system is in a fault zone, a red fault warning will pop up on the human-machine interface. The pop-up window will be locked at the top and cannot be closed, indicating the fault location, risk level, and emergency response plan. The system will output a high-frequency audible and visual warning signal. It will automatically limit the operating load of the equipment, such as reducing the upper limit of the host speed, limiting the increase of heating power, and prohibiting the equipment from operating under high load. It will not execute an emergency shutdown, and the equipment can run under low load for a short time to give the operator buffer time to handle the situation. The fault event will be locked simultaneously, and the load limit can only be released after the fault has been investigated and reset.

[0092] If the system is in a critical fault zone, an emergency fault pop-up window will appear on the human-machine interface, highlighting the core fault item in red; the system will output the highest level of emergency audible and visual warning signal; the safety interlock warning module will immediately execute the standardized safety shutdown procedure: first stop the screw feeding system, then shut down the main motor power output, and finally shut down the heating system zone by zone to achieve emergency shutdown and repair of the equipment; simultaneously lock all operating permissions of the equipment until the fault is completely investigated and manually reset before the equipment can be unlocked to start up, preventing safety accidents caused by operating with faults.

[0093] In addition, the assessment method also includes degradation rules. When the full score for operational health is 100 points, meeting the first-level degradation rule will result in an operational health score of 60 points for the extrusion molding unit, while meeting the second-level degradation rule will result in an operational health score of 0 points for the extrusion molding unit.

[0094] The first-level degradation principle includes any of the following situations: at least three sub-units are simultaneously in the warning range, or any one sub-unit is in the severe fault range. In addition, equipment that continues to operate without completing the troubleshooting of non-shutdown faults is also subject to the first-level degradation principle.

[0095] The Level 2 degradation principle includes any of the following situations: the operations and security unit is in a severe failure range, or the host transmission unit is in a severe failure range. When the Level 2 degradation principle is triggered, the final score is directly determined to be 0.

[0096] The second-level degradation principle has higher priority than the first-level degradation principle. If both are met, the second-level degradation principle is applied.

[0097] Based on the final health score, a corresponding health level and standardized operation and maintenance recommendations are matched.

[0098] For example, a total score of 90-100 points corresponds to an excellent level, indicating that the equipment is in optimal health and routine maintenance recommendations are provided; 80-89 points corresponds to a good level, indicating that the equipment is in good condition and recommendations are provided to continuously monitor parameter trends; 70-79 points corresponds to a fair level, indicating that the equipment has minor anomalies and recommendations are provided to increase inspection frequency and track abnormal parameter trends; 60-69 points corresponds to a warning level, indicating that the equipment has multiple anomalies and recommendations are provided to immediately conduct a comprehensive investigation and prohibit high-load operation; <60 points corresponds to a fault / unqualified level, indicating that the equipment has serious safety hazards and recommendations are provided to immediately stop and repair the equipment, and to implement safety interlocking actions, such as emergency shutdown or direct disconnection of safety coupling 28.

[0099] The aforementioned assessment method establishes a full-link linkage mechanism of health scoring, graded early warning, and safety interlock. It provides a detailed evaluation standard and weighting system that can accurately reflect the operating status of extrusion molding equipment for different functions of different sub-units. Based on the different severity levels of different sub-units, a differentiated equipment feedback mechanism is set up, which not only avoids excessive downtime affecting the continuity of production or experiments, but also eliminates equipment damage and safety accidents under serious abnormalities. For example, a certain important sub-unit has veto power and can directly trigger a shutdown, thereby enabling a comprehensive perception of the operating status of the extrusion unit and accurate early warning, effectively ensuring operational safety.

[0100] Based on the above description of the assessment methods, a health assessment system for extrusion molding equipment can also be understood. This system includes a parameter acquisition unit 300, a main control processing unit 400, and a safety interlock unit 500.

[0101] The parameter acquisition unit 300 includes multiple sub-unit parameter acquisition components, specifically including the host transmission parameter acquisition component 301, the gearbox and load-bearing component parameter acquisition component 302, the temperature control parameter acquisition component 303, the melt process parameter acquisition component 304, the actuator status acquisition component 305, and the operation and maintenance status acquisition component 306.

[0102] The main control processing unit 400 is signal-connected to the parameter acquisition unit 300 and includes a health status quantification and scoring module. This module calculates and outputs a health score and / or health level based on the data acquired by the sub-unit parameter acquisition components. The safety interlock unit 500 is signal-connected to the main control processing unit 400 and is used to execute a shutdown operation based on the health score and / or health level.

[0103] Specifically, the host transmission parameter acquisition component includes the following sensors: a speed sensor installed at the output end of the host drive motor to acquire the host speed setpoint and feedback value; a Hall current sensor installed in the main circuit of the motor to acquire the real-time current value and current load percentage of the motor; and a dynamic torque sensor installed on the output shaft of the motor to acquire the real-time torque value of the motor and the host torque percentage.

[0104] The gearbox and load-bearing component parameter acquisition assembly includes the following sensors: a temperature sensor installed in the gearbox to acquire the gearbox oil temperature; a temperature sensor attached to the bearing housing to acquire the bearing temperature; a vibration sensor installed in the gearbox housing to acquire the gearbox vibration acceleration; a thrust sensor installed in the screw axial direction to acquire the screw axial thrust; an oil metal ion detection sensor installed in the lubrication oil circuit to acquire the metal ion content in the lubrication oil; and torque sensors installed at the bolts of the gearbox clamp and flow channel clamp to acquire the real-time torque values ​​on the left and right sides.

[0105] The temperature control parameter acquisition component includes the following sensors: temperature sensors are installed in the feeding section, plasticizing section, and homogenizing section of the extruder barrel to collect the temperature of the three barrel zones; temperature sensors are installed in the three sections of the die to collect the temperature of the three die zones; and temperature sensors are installed in the cooling water circuits of the screw, barrel, and die to collect the cooling water temperature of each circuit.

[0106] The melt process parameter acquisition component includes the following sensors: a high-temperature melt temperature sensor and a high-temperature melt pressure sensor are installed at the die head to collect the real-time temperature and pressure of the melt; volumetric flow sensors are installed at the screw inlet, barrel outlet, and each flow channel of the die to collect the real-time flow parameters at the corresponding locations.

[0107] The actuator status acquisition component includes the following sensors: an incremental position encoder installed at the output end of the mobile servo motor to acquire the target position and the current position; the current torque percentage acquired at the servo motor driver; and a torque sensor installed at the drive mechanism of the gearbox to acquire the real-time torque value and read the running speed setpoint and torque limit value in the driver.

[0108] The operation and maintenance status acquisition component includes the following sensors: a built-in timing chip to accumulate equipment running time, gear oil change time, and downtime; and a switch quantity acquisition circuit to acquire the switch quantity status of equipment start-up and shutdown, actuator action, and alarm prompt masking.

[0109] The aforementioned data acquisition units are low-cost, and the sensors mostly adopt miniaturized, patch, or clamp-type designs, which are suitable for compact spaces and can effectively reduce costs.

[0110] When the safety interlock unit 500 triggers a shutdown operation based on the rating, it can execute a standardized shutdown procedure: first stop the screw feed, then shut down the main motor, and finally shut down the heating system zone by zone, while locking the equipment operation permissions until the fault is reset.

[0111] The evaluation system also includes a human-computer interaction module with a visual interface, which includes parameter configuration, data import, data visualization and simulation training units.

[0112] The parameter configuration unit allows users to modify equipment ratings, process settings, alarm thresholds, and scoring system weights, and supports saving and one-click import of parameter configuration schemes. The data import unit allows users to update equipment data and synchronize it to the system, allowing users to view historical and current equipment data and displaying the historical operating trends of each parameter. The data visualization unit is divided into seven sections: homepage, host screen, curve screen, half-screen, movement screen, alarm screen, and settings screen. The homepage centrally displays core operating parameters, health scores, and health levels; the host screen displays all parameters of the transmission system; the curve screen displays the historical operating trends of each parameter; the other sections display the parameters and control buttons of the corresponding modules; it also supports the linked display of the equipment 3D model and sensor points. Clicking on a sensor point on the model will bring up the real-time values ​​and trend curves of the corresponding parameter. The simulation training unit has a built-in virtual operating environment completely identical to the extrusion device in this embodiment, setting 15 simulation scenarios in three categories: normal operation, parameter abnormality, and early warning fault. Users can complete the entire system operation in the virtual environment, and the system provides operation guidance and step prompts synchronously, suitable for teaching and training scenarios. The help and guidance unit includes a built-in system operation manual, equipment operation and maintenance specifications, and common fault troubleshooting manual, providing users with full-process operation guidance and technical support.

[0113] When the visual interface is in a simulated operating environment, the operation instructions are not transmitted to the extrusion molding host and only read-only functionality is provided.

[0114] This application uses specific terms to describe embodiments of the application. Terms such as "an embodiment," "one embodiment," and / or "some embodiments" refer to a particular feature, structure, or characteristic associated with at least one embodiment of the application. Therefore, it should be emphasized and noted that references to "an embodiment," "one embodiment," or "an alternative embodiment" in different locations throughout this specification do not necessarily refer to the same embodiment. Furthermore, certain features, structures, or characteristics in one or more embodiments of the application can be appropriately combined.

[0115] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Any variations and modifications can be made by those skilled in the art without departing from the spirit and scope of the invention. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention, without departing from the scope of the invention, fall within the protection scope defined by the claims of the present invention.

Claims

1. An extrusion molding apparatus with dual requirements, characterized in that, include: An extrusion molding machine is used to perform the extrusion production of materials; The control system is connected to the extrusion molding host by a signal. The control system includes a permission management module, which is used to divide the operation permission into production operation and maintenance permission and teaching and training permission. The production operation and maintenance permission corresponds to the production mode, and the teaching and training permission corresponds to the training mode. as well as The simulation training module is used to provide a virtualized operating environment. The simulation training module is configured to provide a simulation operating environment for the entire extrusion molding process. The operating instructions in the simulation operating environment are not transmitted to the extrusion molding host. The control system is configured to allow the production mode and the training mode to run simultaneously or selectively.

2. A method for assessing the operational health of an extrusion molding device, characterized in that, For evaluating an extrusion molding apparatus, the method includes the following steps: S1. Divide the extrusion molding device into multiple sub-units, set independent evaluation criteria for each sub-unit, and assign independent evaluation weight ratios to each sub-unit; S2. Operate the extrusion molding device and collect the operating parameters of each sub-unit in real time; S3. Calculate the health score of the operating parameters of each sub-unit according to the evaluation criteria, and obtain the real-time score of each sub-unit based on the evaluation weight ratio of each sub-unit and the health score; S4. Use the real-time score to determine the operational health of the extrusion molding apparatus.

3. The evaluation method as described in claim 2, characterized in that, The extrusion molding apparatus includes a main drive unit, a gearbox and load-bearing component unit, a temperature control unit, a melt process unit, an actuator unit, and an operation and maintenance and safety unit, such that the sum of the evaluation weight ratios of the main drive unit, gearbox and load-bearing component unit, temperature control unit, melt process unit, actuator unit, and operation and maintenance and safety unit is kept at 100%.

4. The evaluation method as described in claim 3, characterized in that, The evaluation weight ratio of the gearbox and the load-bearing component unit is proportional to their statistical probability of failure; and / or The evaluation weighting of the temperature control unit is proportional to its statistical probability of failure; and / or The evaluation weighting of the melt process unit is proportional to its statistical probability of failure; and / or The evaluation weight ratio of the actuator unit is proportional to its statistical probability of failure.

5. The evaluation method as described in claim 3, characterized in that, The evaluation weight ratios of the main drive unit, the gearbox and load-bearing component unit, the temperature control unit, the melt process unit, the actuator unit, and the operation and maintenance and safety unit are reduced sequentially.

6. The evaluation method as described in claim 3, characterized in that, The evaluation weighting of the temperature control unit is increased based on the material's thermal sensitivity; and / or The evaluation weight ratio of the melt process unit is increased based on the product quality accuracy value.

7. The evaluation method as described in claim 6, characterized in that, The material is polypropylene or polycarbonate, so that the evaluation weight ratio of the main drive unit is the highest, and the evaluation weight ratio of the gearbox and load-bearing component unit is the second highest, or... The material is polyvinyl chloride, so the evaluation weight ratio of the temperature control unit is the highest, and the evaluation weight ratio of the melt process unit is the second highest.

8. The evaluation method as described in claim 3, characterized in that, The weight allocation range for the main drive unit is 20%~30%, the weight allocation range for the gearbox and load-bearing component unit is 15%~25%, the weight allocation range for the temperature control unit is 15%~25%, the weight allocation range for the melt process unit is 10%~20%, the weight allocation range for the actuator unit is 5%~15%, and the weight allocation range for the operation and maintenance and safety unit is 5%~15%.

9. The evaluation method as described in claim 3, characterized in that, Each subunit includes a normal operation range, a warning range, a fault range, and a severe fault range. The health status of each subunit is determined using a real-time score, including the following steps: If the real-time score is not in the warning range, the subunit is determined to be in the normal operating range. If the real-time score is in the warning range but has not reached the fault threshold, the subunit is determined to be in the warning range. If the real-time score exceeds the fault threshold, but the core operating parameters of the subunit are within the normal range, the subunit is determined to be in the fault range. If the core operating parameters of the subunit exceed the safety threshold, the subunit is determined to be in a severe fault range.

10. The evaluation method as described in claim 9, characterized in that, The operational health score is 100 points. The evaluation method also includes degradation rules, which include a first-level degradation rule and a second-level degradation rule. When the first-level degradation rule is reached, the operational health score of the extrusion molding device is 60 points. When the second-level degradation rule is reached, the operational health score of the extrusion molding device is 0 points. The first-level degradation rule includes one of the following: at least 3 sub-units are simultaneously in the warning interval, or any one sub-unit is in the severe fault interval; The secondary degradation rule includes one of the following: the operation and security unit is in a severe fault zone, and the host transmission unit is in a severe fault zone; When both the first-level downgrade rule and the second-level downgrade rule are satisfied, the second-level downgrade rule is executed.

11. A health assessment system for extrusion molding equipment, characterized in that, For performing the method as described in any one of claims 2-10, the system comprises: The parameter acquisition unit includes multiple sub-unit parameter acquisition components; The main control processing unit, signal-connected to the parameter acquisition unit, includes a health status quantification and scoring module. This module calculates and outputs a health score and / or health level based on the data acquired by the parameter acquisition component of the subunit. A safety interlock unit, signal-connected to the main control processing unit, is used to perform a shutdown operation based on the health score and / or health level.

12. The system as claimed in claim 11, characterized in that, The system also includes a human-computer interaction unit, which includes a parameter configuration module and a data visualization module. The parameter configuration module is used to input thresholds and evaluation weight ratios, and the data visualization module is used to display the operating parameters, health scores and early warning information of each sub-unit.

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