Auxiliary material automatic batching monitoring method in industrial internet environment

Abstract

The present application belongs to the technical field of industrial control system, and particularly relates to an auxiliary material automatic batching monitoring method under an industrial internet environment, which comprises the following steps: acquiring real-time dropping height and apparent quality, calculating instantaneous mass flow rate through a short-term observation window, calculating the equivalent mass of air space in combination with the dropping height, removing the equivalent mass of air space from the apparent quality to obtain real static quality, simultaneously acquiring system lag time and calculating the overflow mass of the lag blind area to obtain dynamic feed-forward overshoot mass, comprehensively obtaining estimated mass execution start-stop judgment, cutting off the power supply when the standard is met, and calculating the next step logic trigger delay time. The present application effectively eliminates the false mass caused by the dropping impact, compensates for the software and hardware lag error, and realizes high-precision feed-forward prediction and adaptive timing stepping.

Description

Technical Field

[0001] This invention relates to the field of industrial control system technology. More specifically, this invention relates to an automatic batching and monitoring method for auxiliary materials in an industrial internet environment. Background Technology

[0002] In modern industrial manufacturing, the automated batching of powdered and granular auxiliary materials is a key link in determining the accuracy of product formulation. Such systems rely heavily on programmable logic controllers (PLCs) for the sequential control of underlying actions. That is, under the coordination of the industrial internet, a series of continuous physical production actions are executed in sequence according to predetermined logic, such as material box arrival, feeder start, feeder stop, and material box conveying and removal.

[0003] Currently, the common approach for controlling this batching sequence is to use a programming method that combines a static mass threshold with a fixed-time relay. This means that the control system reads the apparent mass of the weighing sensor in real time. When the mass reaches the preset target static threshold, the PLC immediately issues a command to cut off the power to the feeder. Subsequently, in order to wait for the material suspended in mid-air to fall completely and for the mechanical oscillation of the weighing platform to return to stability, a fixed-duration delay timer is usually connected in series in the PLC program. Only after the fixed delay has ended will the PLC trigger the next removal command.

[0004] However, in actual automated batching scenarios for auxiliary materials, the alternation of material falling due to gravity and equipment start-up and shutdown can lead to false increases in sensor readings due to momentum impact, as well as uncontrollable material overflows due to spatial stagnation and equipment response delays. Traditional static control logic treats the extremely complex dynamic inertial process as an ideal static model, resulting in a serious disconnect between the timing of PLC instruction issuance and the actual physical steady state. Ultimately, this leads to severe distortion of batching results and frequent conflicts in the timing of production actions. Summary of the Invention

[0005] To address the technical problem of traditional sequential control methods neglecting the dynamic physical inertia effect of the material feeding process, leading to a disconnect between instruction execution and the actual physical steady state, resulting in poor batching accuracy and timing conflicts, this invention provides an automatic batching and monitoring method for auxiliary materials in an industrial internet environment. The method includes: acquiring real-time material drop height and apparent mass; calculating the instantaneous mass flow rate based on the difference between the current apparent mass and the apparent mass at the start of a short-term observation window, and the time span of the short-term observation window; calculating the spatial fall time based on gravitational acceleration and the current material drop height, and calculating the equivalent mass in mid-air based on the instantaneous mass flow rate; and then... The difference between the apparent quality and the idling equivalent quality at the previous moment is taken as the true static quality; the bottom-level cyclic scanning cycle and the power-off braking hysteresis time are obtained, and the hysteresis blind zone overflow quality is calculated in combination with the instantaneous mass flow rate; the idling equivalent quality and the hysteresis blind zone overflow quality are summed to obtain the dynamic feedforward overshoot quality; the true static quality and the dynamic feedforward overshoot quality are summed to obtain the estimated quality, which is used to perform start-stop judgment: if the standard is not met, feeding is maintained; if the standard is met, a power cut-off command is issued, and the initial kinetic energy and residual kinetic energy threshold of the falling material impact are calculated to obtain the next logic trigger delay time. After the delay time is exhausted, the next conveyor line removes the material box command is triggered.

[0006] This invention achieves closed-loop control of the entire automatic batching process by analyzing dynamic weighing errors and fully compensating for spatiotemporal lag. Utilizing short-time steady-state characteristics, it removes the downward dynamic impact force generated by materials hitting the weighing platform, restoring the true static net weight. Simultaneously, it comprehensively analyzes the free-fall airborne mass and the lag and overflow of underlying software and hardware responses to construct a predicted mass. This feedforward prediction enables the system to accurately issue cutoff commands before the actual mass reaches the target. Furthermore, it introduces an adaptive flexible timing step based on the laws of physical energy dissipation, avoiding material spillage and wasted production cycle time.

[0007] Preferably, the instantaneous mass flow rate satisfies the expression: In the formula, The instantaneous mass flow rate at the current moment; The apparent quality at the current moment; The apparent quality at the start of the short-term observation window at the current moment; The number of sampling time intervals included in a short-term observation window; The sampling period.

[0008] This invention utilizes the short-time steady-state assumption in fluid dynamics to maintain a constant falling impact force within a short observation window, thereby assessing the true physical flow rate after stripping away the impact camouflage and providing benchmark parameters for constructing a dynamic feedforward model.

[0009] Preferably, the calculation of the spatial fall time includes: the spatial fall time is equal to the square root of the quotient obtained by dividing twice the current drop height by the gravitational acceleration constant.

[0010] Preferably, the calculation of the hang-off equivalent mass includes: multiplying the instantaneous mass flow rate by the spatial descent time to obtain the hang-off equivalent mass.

[0011] This invention captures the illusory mass caused by the momentum impact force generated when the material falls and hits the weighing platform. It then converts this illusory mass into an equivalent spatial hang mass and uses it as a core feedforward compensation factor. This effectively eliminates dynamic impact interference and ensures that the absolute true static mass falling into the material box is restored under severe impact conditions.

[0012] Preferably, the step of obtaining the underlying cyclic scan cycle and the power-off braking hysteresis time includes: obtaining the underlying cyclic scan cycle from the system operation status register parameter table inside the programmable logic controller; performing a hysteresis calibration test under the initial no-load state of the equipment, using a high-speed oscilloscope to collect and obtain the time difference between the moment when the programmable logic controller issues the feeding power-off signal and the moment when the encoder at the end of the feeding drive motor shaft feedbacks that the speed has returned to zero, and using this as the power-off braking hysteresis time.

[0013] Preferably, the calculation of the hysteresis blind zone overflow quality includes: summing the bottom layer cyclic scan cycle and the power-off braking hysteresis time to obtain the total hysteresis time; and multiplying the instantaneous mass flow rate by the total hysteresis time to obtain the hysteresis blind zone overflow quality.

[0014] This invention combines instantaneous mass flow rate to calculate the amount of uncontrollable material continuously overflowing within the software and hardware hysteresis blind zone after a power-off command is issued, thus breaking through the inherent software and hardware execution delay bottleneck of conventional PLCs.

[0015] Preferably, the start / stop judgment includes: obtaining the target quality of the ingredient product from the upper-level MES system; if the estimated quality is less than the target quality, it is determined that the target quality has not been met; if the estimated quality is greater than or equal to the target quality, it is determined that the target quality has been met.

[0016] Preferably, the initial kinetic energy of the material impact is calculated by multiplying the current airborne equivalent mass, the current material drop height, and the gravitational acceleration to obtain the initial kinetic energy of the material impact.

[0017] Preferably, the residual kinetic energy threshold is obtained by: obtaining the upper limit mass of the weighing error allowed by the process and the mechanical stiffness of the weighing platform; multiplying the upper limit mass of the weighing error by the gravitational acceleration to obtain the safety limit force, and then dividing the square of the safety limit force by twice the mechanical stiffness to obtain the residual kinetic energy threshold.

[0018] Preferably, obtaining the next logic trigger delay time includes: if the initial kinetic energy of the material impact at the current moment is less than or equal to the residual kinetic energy threshold, the residual amplitude fluctuation coefficient is 0; if the initial kinetic energy of the material impact at the current moment is greater than the residual kinetic energy threshold, the ratio of the initial kinetic energy to the residual kinetic energy threshold is square rooted, and the residual amplitude fluctuation coefficient is equal to the square root result minus a constant 1; the residual amplitude fluctuation coefficient is multiplied by the underlying loop scan cycle to obtain the next logic trigger delay time.

[0019] This invention maps the energy excess factor to the amplitude excess factor based on physical relationships, greatly reducing the floating-point operation load of the PLC. At the same time, it combines the decrement operation to realize zero-position translation and automatically skips the waiting when the impact force is safe. This architecture upgrades the traditional fixed dead zone waiting to a lightweight adaptive delay, which maximizes the production line operation speed while ensuring weighing accuracy.

[0020] The beneficial effects of this invention are as follows: This invention utilizes the fluid momentum conservation characteristic within an extremely short time to eliminate the false increment of dynamic impact force generated by material impacting the weighing platform, thereby obtaining the true static mass. This effectively eliminates the defect that the actual mass is lower than the set target due to the disappearance of impact force after shutdown. By analyzing the free-fall mass in physical space and the underlying reaction lag and overflow caused by the PLC scanning cycle and mechanical actuator, a feedforward prediction mechanism is constructed to ensure that the power is cut off when the actual mass meets the target. It also adaptively calculates the next logic trigger delay time, transforming the traditional fixed-time dead waiting into an adaptive flexible timing step based on impact energy and program scanning cycle. This mechanism optimizes the production line's operating rhythm and time efficiency while avoiding material spillage. Attached Figure Description

[0021] Figure 1 This is a flowchart of the automatic batching and monitoring method for auxiliary materials in an industrial internet environment according to the present invention; Figure 2 This is a comparison diagram of the control effects of the present invention and the traditional solution. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0024] This invention discloses an automatic batching and monitoring method for auxiliary materials in an industrial internet environment, referring to... Figure 1 This includes steps S1 to S4: S1. Obtain real-time material drop height and surface quality.

[0025] It should be noted that the core of the auxiliary material batching system's program control lies in the accurate perception of physical motion laws. In order for the PLC program to establish an accurate dynamic feedforward model, the primary task is to acquire real-time changing quality information and spatial distance parameters that determine the material's flight characteristics. In addition, since the impact force generated when powder and granular materials fall and hit the weighing platform is a rapidly changing high-frequency transient physical process, if the sampling frequency is too low, key impact characteristics will be missed or signal distortion will occur.

[0026] Specifically, real-time communication is established between the industrial IoT gateway and the PLC system and high-precision weighing sensors of the batching station. A fixed high-frequency sampling period is set, and at each moment after the feeder starts, the force fed back by the weighing sensors under the combined action of the actual weight of the material and the dynamic impact force is collected and recorded in real time. Based on the constant of gravitational acceleration, it is converted into the apparent mass at the current moment. At the same time, the vertical distance from the feeder outlet to the material surface inside the material box is obtained synchronously through a laser rangefinder deployed on the equipment side. The vertical distance is used as the material drop height at the current moment.

[0027] It should be added that the dynamic impact force generated when powdered or granular materials accelerate and fall into the weighing platform is an extremely high-frequency transient signal. After being impacted by the falling material, the inherent mechanical transient oscillation frequency generated by the supporting base of the industrial weighing platform is usually distributed in the range of 10Hz-20Hz. According to the Nyquist theorem of signal sampling and engineering anti-aliasing experience, in order to capture and restore the peak and valley details of this transient impact waveform without distortion and to prevent the omission of key high-frequency impact features, the sampling frequency of the system must reach more than 5 times the maximum value of the physical oscillation frequency. Therefore, this embodiment uses a sampling frequency of 100Hz, that is, a sampling period of 10 milliseconds, which can achieve high-fidelity restoration of the real physical impact process with extremely high redundancy.

[0028] At this point, the real-time material drop height and surface quality are obtained.

[0029] S2. Calculate the real-time instantaneous mass flow rate.

[0030] It should be noted that in the dynamic physical process of automatic batching of powders and granules, the continuous impact of the material group with initial falling velocity on the weighing platform generates continuous momentum exchange, thereby applying an additional downward dynamic impact force. This causes a false positive bias to be superimposed on the apparent mass signal output by the sensor. However, based on the short-time steady-state assumption in fluid dynamics, the feeding mass flow rate of the feeding mechanism can be approximated as a constant value within a very short time scale. According to the momentum theorem, when both the mass flow rate and the falling contact velocity remain constant, the downward dynamic impact force generated by the continuous impact of the material on the weighing platform is also a constant physical constant. This means that within the short-term observation window, the differential increment of the apparent mass of the material box, after eliminating the constant impact force bias, is equivalent to the actual static mass increment falling onto the weighing platform. Therefore, by calculating the differential rate of change of apparent mass within the short-term observation window, the true instantaneous mass flow rate after eliminating impact interference can be evaluated.

[0031] Specifically, taking the current moment as the last moment of the short-term observation window, we obtain the apparent quality of the starting moment within the short-term observation window of the current moment.

[0032] It should be added that the length of the short-term observation window is used to define the effective physical time scale for the control system to perform short-term steady-state assumptions and differential calculations. To ensure that the flow rate does not dynamically decay and the impact force remains constant within the short-term observation window, engineering requires that the length of the short-term observation window be strictly controlled within one-quarter of the minimum absolute airborne flight time of the material. Combined with the minimum drop limit determined by the clearance space of the industrial batching system, which is usually 0.2 meters, and based on the law of free fall, the minimum absolute airborne flight time of the material leaving the discharge port and hitting the weighing platform is about 200 milliseconds. This means that the size of the short-term observation window needs to be less than or equal to 50 milliseconds. Therefore, in this embodiment, the length of the observation window is taken as 5 cycles, which achieves the optimal physical balance between filtering out the high-frequency background noise of the sensor and maintaining the sensitivity of the flow rate dynamic tracking. The implementers can adjust it based on the actual batching system parameters.

[0033] The instantaneous mass flow rate at the current moment is calculated based on the difference between the apparent mass at the current moment and the apparent mass at the start of the short-term observation window, and the time span of the short-term observation window; the specific calculation formula is as follows:

[0034] In the formula, The instantaneous mass flow rate at the current moment; The apparent quality at the current moment; The apparent quality at the start of the short-term observation window at the current moment; The number of sampling time intervals included in a short-term observation window; The sampling period.

[0035] in, It reflects the increase in apparent quality within the short-term observation window at the current moment; This reflects the time span within the short-term observation window at the current moment. Due to the short-term steady state and momentum conservation axiom in fluid dynamics, the impact force of the falling material remains constant within the short-term observation window. This causes the impact force bias in the increment of the apparent mass after subtraction to be canceled out. Therefore, It reflects the actual physical flow rate of the material falling after removing the static superposition error of constant impact force at the current moment. The larger the value, the more absolute physical mass of the material falling into the weighing platform per unit time after removing the impact camouflage at the current moment, which means that the actual discharge efficiency of the equipment outlet is stronger at the current moment.

[0036] At this point, the instantaneous mass flow rate at each moment is obtained.

[0037] S3. Calculate the real-time static quality and dynamic feedforward overshoot quality.

[0038] It should be noted that as a force-bearing element, the weighing sensor can be misled by the momentum impact force generated by the falling material hitting the weighing platform, resulting in an overestimation of the apparent mass. In physics, according to the fluid momentum theorem, the impact force is equal to the product of the mass flow rate and the falling contact velocity. The equivalent spurious mass corresponding to the impact force is exactly numerically equivalent to the mass of the material suspended in the air during this height, i.e., the product of the flow rate and the falling time. Therefore, calculating the total amount of material suspended in the air represents both the spurious mass read by the sensor and the total mass of the suspended material that is currently detached from the feeder and is uncontrolled.

[0039] Specifically, the spatial descent time is derived from the gravitational acceleration and the current drop height. Based on the instantaneous mass flow rate and the spatial descent time at the current moment, the equivalent mass in the air at the current moment is calculated. The specific calculation formula is as follows:

[0040] In the formula, The equivalent mass of hovering at the current moment; The instantaneous mass flow rate at the current moment; This represents the current material drop height. is the gravitational acceleration constant.

[0041] in, It reflects the flight time of the material in the air after it leaves the feeder outlet at the current moment; It reflects the total mass of suspended material falling without physical constraints during the flight time at the current moment. It is also equivalent to the false increment caused by the dynamic impact force generated by the drastic change in momentum when the continuously falling material flow contacts the weighing platform. The larger the value, the higher the installation height or the faster the feeding speed at the current moment, which means that there is more physical margin outside the control of the equipment at the current moment, and the more severe the impact interference on the weighing sensor.

[0042] The difference between the apparent mass at the current moment and the equivalent mass of the hangar at the current moment is taken as the true static mass at the current moment.

[0043] As a force-bearing element, the apparent mass read by the weighing sensor at the current moment is actually a resultant force of two physical quantities: one part is the actual weight of the material that has fallen into the box and is in an absolutely static state, and the other part is the downward dynamic impact force generated by the continuous falling material flow hitting the weighing platform. As deduced from the aforementioned physical momentum theorem, the false mass increment caused by this dynamic impact force is numerically equivalent to the vacant equivalent mass. Therefore, by subtracting the vacant equivalent mass representing the false impact increment from the apparent mass, the dynamic impact interference can be completely removed from the total reading, so as to restore the absolutely true static mass that is currently lying stably in the material box and is not contaminated by any dynamic force.

[0044] It should be further noted that the control loop of the batching system has inherent timing delay characteristics. When the PLC program determines that the quality meets the standard and issues a stop command, the feeding action will not stop instantly. Within the software and hardware hysteresis blind zone formed by the controller execution cycle time and the mechanical locking time of the actuator, the discharge port will continue to discharge material according to the current flow rate inertia. It is necessary to further identify this part of the material that overflows unexpectedly in the blind zone in order to achieve high-precision feedforward compensation.

[0045] Specifically, the underlying cyclic scan cycle is obtained by retrieving it from the system operation status register parameter table inside the PLC controller.

[0046] The power-off braking hysteresis time is obtained by performing a hysteresis calibration test under the initial no-load state of the equipment. The time difference between the moment when the PLC controller sends the power-off signal for feeding and the moment when the encoder at the end of the feeding drive motor shaft returns to zero is collected and obtained using a high-speed oscilloscope. This time difference is used as the power-off braking hysteresis time.

[0047] The hysteresis blind zone overflow mass at the current moment is calculated based on the instantaneous mass flow rate, the underlying cyclic scan cycle, and the power-off braking hysteresis time; the specific calculation formula is as follows:

[0048] In the formula, The current moment represents the overflow quality of the hysteresis blind zone; The instantaneous mass flow rate at the current moment; This is the bottom layer cyclic scan cycle; This refers to the power-off braking hysteresis time.

[0049] in, This reflects the extra amount of material that unexpectedly overflows from the outlet due to the time delay caused by the underlying electrical control response and mechanical braking after the system receives a logic stop signal. The larger this value, the faster the instantaneous material flow rate or the slower the software and hardware braking response at the current moment, which means that more material leaks out uncontrollably in the time blind zone after the command is issued.

[0050] The dynamic feedforward overshoot mass at the current moment is obtained by summing the current moment's equivalent hang time mass and the current moment's hysteresis overflow mass.

[0051] Among them, the hysteresis equivalent mass represents the material that has detached from the equipment and is suspended in the air, while the hysteresis blind zone overflow mass represents the material that will continue to fall during the shutdown delay. These two parts, superimposed on the physical space and time scale, constitute the total overshoot that will inevitably fall into the packaging box after the system stops, and are used as the overall feedforward compensation benchmark.

[0052] At this point, the true static quality and dynamic feedforward overshoot quality at the current moment are obtained.

[0053] S4. The underlying sequence control of the PLC is based on real-time estimated quality.

[0054] It should be noted that traditional PLC control relies solely on the comparison between apparent quality and target quality, lacking the ability to predict physical dynamic evolution, which can easily lead to delayed instruction issuance. Therefore, by constructing an estimated quality that includes hysteresis margin and equipment delay, the PLC can perceive the physical steady state in advance, thereby accurately issuing truncation instructions before the quality truly meets the target, achieving closed-loop control to prevent overshoot.

[0055] Specifically, the target quality of the current batching product is obtained from the upper-level MES system; the estimated quality at the current moment is calculated, which is equal to the sum of the actual static quality at the current moment and the dynamic feedforward overshoot quality at the current moment.

[0056] Among them, the true static mass represents the actual net weight that has now fallen steadily into the material box without being disturbed by the impact force; while the dynamic feedforward overshoot mass represents the total amount of uncontrollable material that will inevitably continue to fall into the material box after the PLC issues a stop command, due to the suspended material in the air and the slow response of the software and hardware. The summation reflects the total absolute static mass that the material box will reach when the power is immediately cut off at the current moment.

[0057] The PLC's underlying sequential control logic is executed based on the estimated quality at the current moment: If the estimated quality at the current moment is less than the target quality of the current batched product, it is determined that the standard has not been met, that is, the shutdown condition has not been met. The system continues to run the feeder and enters the monitoring of the next cycle scan. If the estimated quality at the current moment is greater than or equal to the target quality of the current batched product, it is determined that the standard has been met, that is, the shutdown condition has been met. The PLC immediately issues a command to cut off the power supply to the feeder and causes the logic to jump to the transition waiting stage.

[0058] It should be further explained that after the PLC issues the command to cut off the power to the feeder, it enters a transition waiting stage. At this time, it is necessary to calculate the dynamic timing step delay time to calm the material falling oscillation. Since the irreversible fall of the suspended material will cause impact, if the program triggers the next instruction in a fixed way, it will cause the material to shake violently or even spill. Therefore, it is necessary to combine the discrete execution logic at the bottom layer of the system to calculate the waiting timing.

[0059] Specifically, the initial kinetic energy of the material impact at the current moment is calculated by multiplying the equivalent mass of the material in the air at the current moment, the material drop height at the current moment, and the gravitational acceleration.

[0060] The residual kinetic energy threshold is obtained by: obtaining the upper limit mass of the weighing error allowed by the process and the mechanical stiffness of the weighing platform; based on the physical relationship between elastic potential energy and force, multiplying the upper limit mass of the weighing error allowed by the gravitational acceleration to obtain the safety limit force, and then dividing the square of the safety limit force by twice the mechanical stiffness of the weighing platform to obtain the residual kinetic energy threshold.

[0061] Furthermore, the residual amplitude fluctuation coefficient at the current moment is calculated. This coefficient is used to measure whether the degree of mechanical sway caused by the current impact energy exceeds the system's tolerance boundary. The specific calculation logic is as follows: Determine the relationship between the initial kinetic energy and the residual kinetic energy threshold of the material impact at the current moment: If the initial kinetic energy of the material impact at the current moment is less than or equal to the residual kinetic energy threshold, the physical determination is that the current impact is insufficient to trigger effective oscillation, and the system is in an absolutely safe steady state. At this time, the residual amplitude fluctuation coefficient is 0. If the initial kinetic energy of the material impact at the current moment is greater than the residual kinetic energy threshold, it indicates that the energy generated by the current macroscopic material impact has exceeded the system's tolerance limit, which will inevitably cause mechanical oscillation of the weighing platform and lead to distorted readings of the weighing sensor. At this time, based on the physical relationship between the elastic potential energy and the square of the oscillation amplitude in the mechanical spring damping system, that is, the energy is proportional to the square of the amplitude, the square root of the ratio of the initial kinetic energy of the material impact at the current moment to the residual kinetic energy threshold is calculated, thereby mapping the energy excess multiple to the mechanical amplitude excess multiple. Then, the result of the square root calculation is subtracted from the constant 1 and shifted to the reference zero position to obtain the residual amplitude fluctuation coefficient.

[0062] The physical essence of subtracting 1 when the system exceeds the limit is to strip away the inherent safety margin of the system and allocate attenuation time only to the pure overflow amplitude. This can avoid excessive waiting caused by requiring the weighing platform to be completely still, thereby squeezing the cycle time of each batching cycle to the extreme.

[0063] The underlying cyclic scan cycle is weighted based on the residual amplitude fluctuation coefficient at the current moment to calculate the next logic trigger delay time at the current moment; the specific calculation formula is as follows:

[0064] In the formula, This is the delay time for triggering the next logical step at the current moment; This is the bottom layer cyclic scan cycle; This represents the residual amplitude fluctuation coefficient at the current moment.

[0065] in, This reflects the actual mechanical oscillation amplitude of the weighing platform caused by the impact of falling materials, exceeding the pure overflow multiple of the system's inherent safety tolerance boundary; This reflects the absolute physical waiting time that the system must expend to cut off the false weight interference caused by this dynamic impact and restore the weighing platform to a relatively safe steady state that meets the accuracy requirements. By linearly weighting the underlying scan cycle with the amplitude exceeding the standard multiple, the system transforms the complex mechanical energy dissipation process into dynamic timing parameters that can be directly called by the PLC timer. This allows the control program to no longer rely on the inefficient and conservative fixed dead time, but to adaptively adjust according to the actual intensity of each material impact, achieving a perfect unity of flexible control and cycle pressing.

[0066] When the PLC logic jumps to the transition waiting stage, the program no longer calls the time relay with a fixed value, but instead calls the dynamic timer function block and assigns the delay time of the next logic trigger at the current moment to the dynamic timer as the waiting end point. When the dynamic countdown is exhausted, the program physically determines that the mechanical vibration has completely returned to zero and all the suspended materials have fallen steadily, and immediately triggers the next conveyor line to remove the material box instruction, thereby achieving high-speed and precise coordination.

[0067] For example, Figure 2This graph compares the control effects of the present invention and the traditional method. The horizontal axis represents the feeding time, and the vertical axis represents the mass. Due to the dynamic impact force caused by the falling powdery material hitting the weighing platform, the apparent mass curve in the graph is always higher than the actual static mass curve of the present invention. In the traditional method, the apparent mass falsely reaches the 50kg threshold at 4.8s due to the impact force, triggering a shutdown. Affected by the software and hardware hysteresis blind zone and the material stuck in the air, the actual static mass continues to climb to about 53kg before stabilizing, forming a significant overshoot error zone. In contrast, at 4.5s, the present invention calculates and estimates the mass in advance to determine if the target has been met, triggering the shutdown point. By compensating for the equivalent mass stuck in the air and the overflow mass from the hysteresis blind zone, the actual mass finally falls to the target mass line after 5s, avoiding waste caused by material overshoot and providing a stable physical steady state for subsequent production processes, thus improving the overall cycle time and accuracy of industrial automation.

Claims

1. A method for automatic batching and monitoring of auxiliary materials in an industrial internet environment, characterized in that, include: Obtain real-time material drop height and surface quality; The instantaneous mass flow rate is calculated based on the difference between the apparent mass at the current moment and the apparent mass at the start of the short-term observation window, and the time span of the short-term observation window. The spatial descent time is calculated based on gravitational acceleration and the current drop height, and the equivalent mass in the air is calculated in combination with the instantaneous mass flow rate; the difference between the apparent mass at the current moment and the equivalent mass in the air is taken as the true static mass; the bottom layer cyclic scanning cycle and the power-off braking hysteresis time are obtained, and the hysteresis blind zone overflow mass is calculated in combination with the instantaneous mass flow rate; the equivalent mass in the air and the hysteresis blind zone overflow mass are summed to obtain the dynamic feedforward overshoot mass; The estimated quality is obtained by summing the actual static quality and the dynamic feedforward overshoot quality, and this is used to determine the start / stop operation: if the target is not met, the feeding is maintained. If the target is met, a power cut-off command is issued, and the initial kinetic energy and residual kinetic energy thresholds of the material impact are calculated to obtain the next logic trigger delay time. After the delay time is exhausted, the next command to remove the material box from the conveyor line is triggered.

2. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The instantaneous mass flow rate satisfies the expression: ； In the formula, The instantaneous mass flow rate at the current moment; The apparent quality at the current moment; The apparent quality at the start of the short-term observation window at the current moment; The number of sampling time intervals included in a short-term observation window; The sampling period.

3. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The calculation of the spatial fall time includes: The time of spatial descent is equal to the square root of the quotient obtained by dividing twice the current drop height by the constant of gravitational acceleration.

4. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The calculation of the equivalent mass of hovering includes: Multiplying the instantaneous mass flow rate by the spatial descent time yields the hang-time equivalent mass.

5. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The acquisition of the underlying cyclic scan cycle and the power-off braking hysteresis time includes: Obtain the underlying cyclic scan cycle from the system operation status register parameter table inside the programmable logic controller; perform hysteresis calibration test under the initial no-load state of the equipment, and use a high-speed oscilloscope to collect and obtain the time difference between the moment when the programmable logic controller issues the feeding power-off signal and the moment when the encoder at the end of the feeding drive motor shaft feedbacks that the speed has returned to zero, and use it as the power-off braking hysteresis time.

6. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The calculation of hysteresis blind zone overflow quality includes: The total hysteresis time is obtained by summing the bottom-level cyclic scan cycle and the power-off braking hysteresis time; the hysteresis blind zone overflow mass is obtained by multiplying the instantaneous mass flow rate by the total hysteresis time.

7. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The execution start / stop determination includes: The target quality of the ingredients is obtained from the upper-level MES system. If the estimated quality is less than the target quality, it is determined that the product has not met the standard; if the estimated quality is greater than or equal to the target quality, it is determined that the product has met the standard.

8. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The calculation method for the initial kinetic energy of the material impact is as follows: The initial kinetic energy of the impact is obtained by multiplying the current airborne equivalent mass, the current drop height, and the gravitational acceleration.

9. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The residual kinetic energy threshold is obtained as follows: Obtain the upper limit mass of the weighing error allowed by the process and the mechanical stiffness of the weighing platform; multiply the upper limit mass of the weighing error by the gravitational acceleration to obtain the safety limit force, and then divide the square of the safety limit force by twice the mechanical stiffness to obtain the residual kinetic energy threshold.

10. The method for automatic batching and monitoring of auxiliary materials in an industrial internet environment according to claim 1, characterized in that, The step of obtaining the next logic trigger delay time includes: If the initial kinetic energy of the material impact at the current moment is less than or equal to the residual kinetic energy threshold, the residual amplitude fluctuation coefficient is 0; if the initial kinetic energy of the material impact at the current moment is greater than the residual kinetic energy threshold, the square root of the ratio of the initial kinetic energy to the residual kinetic energy threshold is calculated, and the residual amplitude fluctuation coefficient is equal to the square root result minus a constant 1; the residual amplitude fluctuation coefficient is multiplied by the underlying loop scan cycle to obtain the next logic trigger delay time.

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