A biscuit production line synchronous control method and system

Abstract

This application relates to the field of food automation production technology, and discloses a synchronous control method and system for a biscuit production line. The method includes acquiring the real-time acceleration of the biscuit production line, the preset specifications of the new product, and the falling time of the filling material; calculating the movement distance of the target support position within the falling time of the filling material based on the real-time acceleration and the falling time of the filling material; determining the expected landing position of the filling material on the new product supported by the target support position based on the movement distance and the preset initial landing position of the filling material on the new product supported by the target support position; calculating the landing boundary of the filling material based on the preset specifications of the new product; comparing the expected landing position with the landing boundary, and adjusting the filling cutting trigger timing in the next control cycle based on the comparison result. By combining the landing boundary comparison, the timing is actively adjusted to ensure dynamic synchronization between the filling action and the main machine speed, avoiding cross-pitch misalignment.

Description

Technical Field

[0001] This application relates to the field of food automation production technology, and more specifically, to a synchronous control method and system for a biscuit production line. Background Technology

[0002] After switching between different specifications of biscuit in an automated production line, it is usually necessary to re-establish the synchronization between the filling action and the machine speed. Current processes typically verify the spatial correspondence between extrusion, cutting, and unloading at low speeds, then gradually increase the machine speed to restore normal production capacity. In the production of larger pitch products, the allowable landing space and time window between adjacent bearing positions is relatively generous, and slight timing deviations do not cause serious misalignment. However, when switching to smaller pitch products and entering an accelerated production phase, the number of bearing positions per unit time increases, and the effective landing window for a single bearing position is significantly shortened. In this scenario, the machine speed continuously changes from the formation of the filling material to its landing point, and the target bearing position continuously undergoes relative displacement before the material arrives. Due to the limited dynamic response capability of existing methods in the initial stage of product switching, the landing point reference position often cannot be updated with high-frequency boundaries for the new pitch target in a timely manner. This causes the landing point error, which was acceptable under small drifts, to be rapidly amplified under the tight boundaries of small pitches. This can cause the filling to fall onto the edge or press the edge of the dough, or even be misplaced into adjacent pitch positions, completely disrupting the correspondence between the cutting cycle and the product pitch. Existing conventional control methods tend to treat small pitches as simple parameter scaling, failing to establish effective boundary protection and target dynamic reset mechanisms for the rapid compression phenomenon of the window when non-steady-state acceleration period overlaps with compact space boundaries.

[0003] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this application provides a synchronous control method and system for a biscuit production line. This method can solve the technical problem that, in scenarios where production is switched to small-pitch biscuits and capacity is gradually restored, the effective window of the landing point is rapidly compressed and cross-pitch deviation occurs because the landing point reference position does not promptly receive the new pitch target.

[0005] In a first aspect, this application provides a synchronous control method for a biscuit production line, comprising: The system acquires real-time acceleration data of the biscuit production line, preset specifications of new products, and the time taken for filling materials to fall. Based on real-time acceleration and the falling time of the sandwich material, the moving distance of the target bearing position within the falling time of the sandwich material is calculated. Based on the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target bearing position, the expected landing position of the sandwich material on the new product supported by the target bearing position is determined. Calculate the landing point boundary of the sandwich material based on the preset specifications of the new product; Compare the expected landing point with the landing point boundary, and adjust the sandwich cut-off trigger timing in the next control cycle based on the comparison result.

[0006] This technical solution enables the dynamic calculation of bearing position drift and prediction of landing point position during the non-steady transition period of production speed-up by acquiring key parameters such as acceleration, spacing, and descent time in real time. Combined with landing point boundary comparison, it achieves proactive timing adjustment, thereby solving the window compression problem caused by untimely landing point reference position reception, ensuring dynamic synchronization and matching between the sandwich action and the main machine speed, and avoiding cross-pitch misalignment.

[0007] Optionally, the step of calculating the movement distance of the target bearing position within the falling time of the sandwich material, based on real-time acceleration and the falling time of the sandwich material, includes: During the falling process of the sandwich material, the moment of sandwich cutting is taken as the starting point of integration, and the time from the moment of sandwich cutting to the end of the falling time of the sandwich material is taken as the integration interval. Combined with the real-time speed of the biscuit production line at the integration starting point, the real-time acceleration is integrated twice to calculate the moving distance of the target bearing position.

[0008] Optionally, the step of calculating the landing point boundary of the sandwich material based on the preset specification parameters of the new product includes: Obtain the allowable process offset for the new product; Based on preset specifications and allowable process offsets, the boundary of the allowable drop point for sandwich material on a single bearing position is calculated.

[0009] Optionally, after determining the expected landing position of the sandwich material on the new product supported by the target bearing position based on the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target bearing position, the method includes: The movement distance is converted into the phase offset of the servo actuator in the biscuit production line by the mechanical transmission ratio; Between each control cycle, the phase offset is dynamically superimposed onto the phase register of the servo actuator to offset the movement distance of the target bearing position.

[0010] By using the phase mapping of the mechanical transmission ratio and the dynamic superposition mechanism of the register, the abstract spatial displacement is transformed into a phase command that the servo system can execute, thereby realizing real-time physical cancellation of the load position drift and ensuring that the actuator can respond to position correction requirements at high frequency.

[0011] Optionally, the steps of comparing the expected landing point with the landing point boundary and adjusting the sandwich cutoff trigger timing in the next control cycle based on the comparison result include: Calculate the physical distance between the expected landing point and the landing point boundary; Obtain the real-time speed of the cookie production line and convert the physical distance into landing point tolerance time based on the real-time speed; If the error tolerance time is less than the preset critical threshold, the sandwich cut-off trigger timing in the next control cycle will be adjusted; otherwise, the current sandwich cut-off trigger timing will be maintained.

[0012] By converting spatial boundary margins into time-dimensional fault tolerance time and setting critical thresholds for prediction, intervention mechanisms can be triggered within a safe time window before physical boundary breaches occur, thus realizing a shift in control logic from passive response to proactive prevention.

[0013] Optionally, the step of triggering the sandwich cut-off trigger timing in the next control cycle includes: Calculate the rate of change of the distance between the expected landing point and the landing point boundary over time; Based on the rate of change, calculate the global time advance before the start of the next control cycle; Based on the global time advance, the sandwich cut-off trigger timing in the next control cycle is reconstructed.

[0014] By introducing trend prediction of the rate of change and calculation of global time advance, the dynamic trend of boundary approach can be perceived in advance, and the timing reference can be adjusted in advance before the start of the next cycle, leaving sufficient adjustment margin for high-frequency compensation.

[0015] Optionally, the step of converting physical distance into landing point tolerance time based on real-time velocity includes: When the absolute value of the real-time acceleration is less than the preset dead zone threshold, the physical distance is divided by the real-time velocity to obtain the landing point tolerance time. When the real-time acceleration is greater than or equal to the preset dead zone threshold, the landing point tolerance time is calculated based on the uniform acceleration motion formula, using physical distance, real-time velocity, and real-time acceleration.

[0016] By setting a dead zone threshold to distinguish motion states, linear simplified calculations are used to ensure real-time performance in uniform or slightly accelerated scenarios, while nonlinear kinematic models are used to ensure accuracy in high-acceleration scenarios, thus achieving a balance between computational efficiency and prediction accuracy.

[0017] Optionally, after the step of calculating the landing point tolerance time using physical distance, real-time velocity, and real-time acceleration based on the uniformly accelerated motion formula, the following is included: If the calculated landing point tolerance time based on the uniform acceleration motion formula, using physical distance, real-time velocity, and real-time acceleration, is less than zero, then it is determined that there is a conflict in the input data, the landing point tolerance time is forcibly set to zero, and an out-of-bounds warning is output; otherwise, the calculated landing point tolerance time is used directly.

[0018] By adding a validity check for the calculation results and a forced zeroing mechanism, a safety alarm can be triggered immediately when sensor data is abnormal or parameter conflicts cause calculation distortion, preventing erroneous data from entering the control loop and causing the equipment to malfunction.

[0019] Optionally, the steps for reconstructing the sandwich cutoff trigger timing in the next control cycle based on the global timing advance include: Based on the global timing advance and the angular velocity of the servo actuator of the biscuit production line, the global timing advance is converted into the phase angle advance of the sandwich cutting trigger in the next control cycle; Extract the phase angle of the servo actuator at the end of the current control cycle as the first constraint condition; Add the phase angle of the servo actuator at the end of the current control cycle to the phase angle forward shift to obtain the target phase angle as the second constraint condition; Based on the polynomial spline interpolation algorithm, a smooth transition curve is planned with time as the horizontal axis and the phase angle of the servo actuator as the vertical axis, so that the phase angle smoothly transitions from the first constraint condition to the second constraint condition. The smooth transition curve is discretized and sent to the servo actuator so that the sandwich cut-off trigger time of the next control cycle is advanced accordingly.

[0020] By introducing a spline interpolation algorithm for phase trajectory planning, the continuity of velocity and acceleration is guaranteed while satisfying position constraints, avoiding mechanical shocks caused by phase jumps and achieving a flexible transition in timing adjustments.

[0021] Secondly, this application also discloses a biscuit production line synchronization control system for executing the biscuit production line synchronization control method as described in any of the first aspects, the system comprising: The parameter acquisition module is used to acquire the real-time acceleration of the biscuit production line, the preset specifications of new products, and the falling time of the filling material; The expected landing position generation module is used to calculate the moving distance of the target support position within the falling time of the sandwich material based on real-time acceleration and the falling time of the sandwich material. Based on the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target support position, the expected landing position of the sandwich material on the new product supported by the target support position is determined. The landing point boundary calculation module is used to calculate the landing point boundary of the sandwich material based on the preset specification parameters of the new product. The control module is used to compare the expected landing point with the landing point boundary, and adjust the sandwich cut-off trigger timing in the next control cycle based on the comparison result.

[0022] This application acquires the production line acceleration, the preset specifications of the new product, and the falling time of the sandwich material in real time during the production changeover period. Based on the real-time acceleration, it calculates the movement distance of the target bearing position during the material's fall, determines the expected landing position by combining the preset initial landing position, and calculates the landing boundary according to the preset specifications of the new product. By comparing the expected landing position with the landing boundary, it adjusts the sandwich cutting trigger timing of the next control cycle. By introducing acceleration integral calculation and dynamic boundary comparison mechanisms, a composite control architecture combining feedforward compensation and feedback adjustment during the non-steady-state acceleration period is established. Compared with the window compression problem caused by the inability to update the landing reference position in time in the prior art, this application can track the dynamic drift of the bearing position in real time during the continuous acceleration of the host, predict the landing deviation in advance, and perform fault tolerance assessment in the time dimension. Thus, it can proactively adjust the action timing of the next cycle before physical overshoot occurs, effectively avoiding sandwich edge pressing or cross-pitch misalignment, and significantly improving the stability of the action chain and production continuity of small-pitch products during the acceleration process. Attached Figure Description

[0023] Figure 1 This is a flowchart illustrating a synchronous control method for a biscuit production line provided in an embodiment of this application.

[0024] Figure 2 This is a schematic diagram of the structure of a synchronous control system for a biscuit production line provided in an embodiment of this application.

[0025] Labeling Explanation: 210, Parameter Acquisition Module; 220, Expected Landing Point Position Generation Module; 230, Landing Point Boundary Calculation Module; 240, Control Module. Detailed Implementation

[0026] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, and not all embodiments. The components of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0027] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0028] In automated biscuit production lines, a changeover operation is typically required when switching between different product batches. After the changeover, to ensure product quality and production efficiency, the synchronization between the filling action and the machine speed needs to be re-established. The traditional approach is to verify the spatial correspondence between extrusion, cutting, and material dropping at low speeds, then gradually increase the machine speed to restore normal capacity. However, this traditional synchronization control method has significant limitations in practical applications. Especially when producing larger pitch products, the allowable landing space and time window between adjacent bearing positions are relatively ample, so even slight timing deviations do not lead to serious misalignment problems. However, when the production line switches to smaller pitch products and enters an accelerated production phase, the number of bearing positions per unit time increases, resulting in a significant shortening of the effective landing window for the filling material at a single bearing position. In this scenario, the machine speed continuously changes from the formation of the filling material to its landing point, and the target bearing position continuously undergoes relative displacement before the material arrives. Due to the limited dynamic response capability of existing control methods in the initial stage of changeover, the landing point reference position often cannot be updated with high-frequency boundaries for the new pitch target in a timely manner. This causes the landing point error, which was acceptable under small drift, to be rapidly amplified under tight pitch boundaries. This amplification effect not only causes the filling material to fall onto the edge or pressing edge of the blank, but may even cause it to fall completely into the adjacent pitch position, thereby completely disrupting the correspondence between the filling cutting cycle and the product pitch, seriously affecting product quality and production efficiency. Existing conventional control methods tend to treat small pitches as simple parameter scaling, failing to establish effective boundary protection and target dynamic reset mechanisms for the rapid compression phenomenon of the window when non-steady-state acceleration period overlaps with tight spatial boundaries.

[0029] Regarding this, firstly, see... Figure 1 This application proposes a synchronous control method for a biscuit production line, used during the transition between batches of products of different specifications, including: S1. Obtain the real-time acceleration of the biscuit production line, the preset specifications of the new product, and the falling time of the filling material; S2. Based on real-time acceleration and the falling time of the sandwich material, calculate the moving distance of the target bearing position within the falling time of the sandwich material. Based on the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target bearing position, determine the expected landing position of the sandwich material on the new product supported by the target bearing position. S3. Calculate the landing point boundary of the sandwich material according to the preset specifications of the new product; S4. Compare the expected landing point with the landing point boundary, and adjust the sandwich cut-off trigger timing in the next control cycle based on the comparison result.

[0030] A biscuit production line refers to a complete set of equipment used for automated biscuit production. It typically includes a conveyor belt, a filling extrusion device, a cutting device, and a support position. The support position is used to support the biscuit blanks and transport them to the designated landing point for the filling material. Real-time acceleration refers to the instantaneous acceleration of the biscuit production line at a given moment, reflecting the rate of change in the production line's speed. Preset specifications for new products may include the preset center-to-center distance between two adjacent biscuit blanks on the production line when producing new specifications. The falling time of the filling material refers to the time required for the filling material to fall freely to the target support position after being cut by the filling cutting device.

[0031] The target support position refers to a specific location on the biscuit production line used to support the filling material during its descent. The preset initial landing position refers to the expected landing position of the filling material on the new product supported by the target support position under ideal synchronization. The filling cutting trigger sequence refers to the time sequence that controls the cutting action of the filling material, which directly affects the landing position of the filling material. The control cycle refers to the time interval between one complete control cycle of the biscuit production line synchronous control system.

[0032] Specifically, various methods can be used to acquire real-time acceleration of the biscuit production line, preset specifications of new products, and the time it takes for the filling material to fall. For example, real-time acceleration can be acquired using encoders or accelerometers installed on the servo motors of the biscuit production line. These sensors can monitor the rate of change of speed on the production line in real time and transmit the data to the control system. Preset specifications of new products are usually stored in the database of the control system and are selected by the operator or automatically loaded by the system during changeover. The time it takes for the filling material to fall can be obtained through experimental measurement or calculation based on a physical model. For example, a high-speed camera can be used to record the time it takes for the filling material to fall from the cut to the bearing position, or it can be estimated based on the initial velocity, falling height, and gravitational acceleration of the filling material.

[0033] To calculate the distance the target support position moves during the falling time of the sandwich material, based on real-time acceleration and the falling time of the sandwich material, and to determine the expected landing position of the sandwich material on the new product supported by the target support position, the following can be implemented: First, using real-time acceleration and the falling time of the sandwich material, the displacement of the target support position during this time is calculated using kinematic formulas. For example, if we assume the production line is undergoing uniform acceleration during this short period, the moving distance can be calculated using the formula s=v0*t+0.5*a*t^2, where v0 is the real-time velocity at the moment of sandwich cutting, a is the real-time acceleration, and t is the falling time. Then, by superimposing the calculated moving distance with the preset initial landing position, the expected landing position of the sandwich material on the new product supported by the target support position can be obtained. For example, if the preset initial landing position is the center of the biscuit blank, and the target support position moves forward by a distance x, then the expected landing position will be the position x positions backward from the center of the biscuit blank.

[0034] Calculating the landing point boundary of the filling material based on the preset specifications of the new product can be achieved as follows: Based on the preset specifications of the new product, the theoretical space occupied by a single biscuit blank on the production line can be determined. On this basis, considering the actual size of the biscuit blank and the allowable offset of the filling material's landing point in the process, the effective area that the filling material is allowed to fall into at a single bearing position, i.e., the landing point boundary, can be calculated. For example, if the preset specification parameter, i.e., the diameter of the biscuit blank, is D, and the allowable offset in the process is E, then the landing point boundary can be defined as a range of (D / 2 - E) to the left and right of the center of the biscuit blank, to avoid falling into adjacent biscuit blanks.

[0035] In comparing the expected landing point with the landing point boundary and adjusting the sandwich cut-off trigger timing in the next control cycle based on the comparison result, the following approach can be used: Compare the calculated expected landing point with the preset landing point boundary. If the expected landing point falls within the landing point boundary, the current synchronization is considered good, and no adjustment is needed. If the expected landing point exceeds the landing point boundary, it indicates a synchronization deviation, and the adjustment amount of the sandwich cut-off trigger timing in the next control cycle needs to be calculated based on the magnitude and direction of the deviation. For example, if the expected landing point is too early, the sandwich cut-off trigger timing needs to be appropriately delayed; if the expected landing point is too late, the sandwich cut-off trigger timing needs to be appropriately advanced. The magnitude of the adjustment can be proportional to the deviation, or it can be dynamically adjusted using algorithms such as PID control.

[0036] The core innovation of the synchronous control method for a biscuit production line proposed in this application lies in the introduction of dynamic sensing of the real-time acceleration of the production line and accurate prediction of the expected landing position of the filling material, combined with closed-loop adjustment based on the dynamic landing point boundary. By acquiring the real-time acceleration of the biscuit production line and calculating the movement distance of the target bearing position within the falling time of the filling material, the expected landing position of the filling material is accurately predicted. By comparing the predicted expected landing position with the dynamic landing point boundary and adjusting the filling cutting trigger timing in the next control cycle based on the comparison result, this application can achieve precise and real-time control of the landing position of the filling material.

[0037] Furthermore, the step of calculating the movement distance of the target bearing position within the falling time of the sandwich material, based on real-time acceleration and the falling time of the sandwich material, includes: During the falling process of the sandwich material, the moment of sandwich cutting is taken as the starting point of integration, and the time from the moment of sandwich cutting to the end of the falling time of the sandwich material is taken as the integration interval. Combined with the real-time speed of the biscuit production line at the integration starting point, the real-time acceleration is integrated twice to calculate the moving distance of the target bearing position.

[0038] Specifically, the filling-cutting moment refers to the instant the filling material is cut from the filling mechanism and begins to fall freely. This moment is chosen as the integration starting point because from this moment on, the filling material begins to move independently of the filling mechanism, while the target bearing position, i.e., the biscuit blank carrying the new product, continues to move on the biscuit production line. The integration interval refers to the time period from the filling-cutting moment until the filling material has completely fallen and contacts the new product on the target bearing position; the length of this time period is the falling time of the filling material. The real-time velocity of the biscuit production line at the integration starting point refers to the instantaneous velocity of the target bearing position at the instant the filling material is cut. Double integration of the real-time acceleration refers to converting the acceleration signal into a displacement signal through two integration operations. The first integration converts acceleration into velocity change, and the instantaneous velocity is obtained by combining the real-time velocity at the starting point of integration. The second integration converts instantaneous velocity into displacement change, thereby accurately calculating the distance the target bearing position moves during the entire falling time of the sandwich material. This can accurately quantify the actual displacement of the target bearing position during the falling of the sandwich material, providing accurate input for determining the expected landing point.

[0039] This application employs a quadratic integral method to calculate the movement distance of the target bearing position, enabling a more accurate reflection of the dynamic motion characteristics of the filling material during its descent in a biscuit production line. Traditional methods may only consider average speed or assume a constant speed, neglecting the continuous influence of acceleration on velocity and displacement. By using the moment of filling cutting as the starting point for integration and combining it with the real-time velocity at that moment, the quadratic integral can accurately convert the cumulative effect of real-time acceleration over the entire descent time into a displacement. This allows for accurate capture of the actual movement of the target bearing position even during transitions where production line speed and acceleration frequently change, thus providing high-precision basic data for calculating the expected landing position of the filling material.

[0040] In some preferred embodiments, it is assumed that during a product batch changeover transition, the biscuit production line is accelerating from a low speed to a high speed. When the filling material is cut, i.e., at the integration starting point, the real-time velocity of the biscuit production line at the filling-cutting position is V0, and the real-time acceleration is a(t), where t is the time from the moment of filling cut. The time taken for the filling material to fall is T. To accurately calculate the distance S that the target bearing position moves within time T, firstly, the real-time acceleration a(t) is integrated for the first time to obtain the velocity change ΔV(t) = ∫a(t)dt. Then, this velocity change is added to the real-time velocity V0 at the integration starting point to obtain the instantaneous velocity V(t) = V0 + ΔV(t). Finally, the instantaneous velocity V(t) is integrated for the second time to obtain the moving distance S = ∫V(t)dt, with the integration interval [0, T]. For example, if the real-time acceleration a(t) is a constant a, then the moving distance S = V0 * T + 0.5 * a * T^2. If the acceleration is a function that varies with time, it can be calculated using numerical integration or analytical integration.

[0041] This application further proposes that the steps for calculating the landing point boundary of the sandwich material based on the preset specification parameters of the new product include: Obtain the allowable process offset for the new product; Based on preset specifications and allowable process offsets, the boundary of the allowable drop point for sandwich material on a single bearing position is calculated.

[0042] Specifically, preset specification parameters refer to the geometric dimensions of the new product's biscuit blank, such as its length, width, or diameter. The allowable process offset refers to the maximum acceptable deviation of the filling material's landing point from its ideal position during actual production, caused by factors such as mechanical precision, material characteristics, or environmental factors. It reflects the production system's tolerance for errors while ensuring product quality. When calculating the allowable landing point boundary for filling material at a single bearing position, the effective bearing area for each biscuit blank can be determined based on the biscuit blank specification parameters. Furthermore, by introducing the allowable process offset, this effective bearing area can be appropriately contracted or expanded, resulting in a more precise and practically feasible landing point boundary. For example, the landing point boundary can be defined as the range obtained by subtracting half the length or half the width of the biscuit blank and the allowable process offset from the center of the biscuit blank.

[0043] As a specific implementation, assuming the biscuit dough length is 80 mm and the process allows for an offset of ±5 mm, the calculation process for the allowable drop point boundary of the filling material on a single bearing position is as follows: First, taking the center of the cookie dough as a reference point, the ideal bearing area length is 80 mm of the cookie dough length.

[0044] Secondly, considering that the process allows for an offset of ±5 mm, this means that the landing point of the filling material can be offset by 5 mm to each side from the effective bearing area of ​​the biscuit blank.

[0045] Therefore, the effective landing point range of the filling material will extend from the center of the biscuit blank to both sides, and its boundary can be calculated as: center position ± (biscuit blank length / 2 - process allowable offset).

[0046] Specifically, if the center of the cookie dough is taken as point 0, then the boundary of the landing point is [-(80 / 2-5),+(80 / 2-5)]=[-(40-5),+(40-5)]=[-35 mm,+35 mm].

[0047] This means that the intended landing point of the filling material must fall within the range of -35 mm to +35 mm from the center of the biscuit blank in order to be considered a valid landing.

[0048] Further, after determining the expected landing position of the sandwich material on the new product supported by the target bearing position based on the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target bearing position, the process includes: The movement distance is converted into the phase offset of the servo actuator in the biscuit production line by the mechanical transmission ratio; Between each control cycle, the phase offset is dynamically superimposed onto the phase register of the servo actuator to offset the movement distance of the target bearing position.

[0049] Specifically, the mechanical transmission ratio refers to the transmission ratio of mechanical components such as gears and belts in a biscuit production line, used to convert linear movement distance into the rotation angle or phase of the servo actuator. The servo actuator is a key component controlling the movement of the biscuit production line; for example, a servo motor's movement is precisely controlled by its phase angle. The phase offset is a value calculated based on the movement distance of the target bearing position, requiring adjustment of the current phase of the servo actuator. The control cycle refers to the time interval for the synchronous control system of the biscuit production line to complete one complete control cycle. The phase register is a digital register inside the servo actuator used to store the current phase angle command. Dynamically adding the phase offset to the phase register means that within each control cycle, the phase command of the servo actuator is corrected in real time based on the calculated movement distance, ensuring that the servo actuator's movement trajectory accurately offsets the movement of the target bearing position, guaranteeing that the filling material falls accurately into the preset position of the new product.

[0050] In some preferred embodiments, it is assumed that during the transition period of product specification change in the biscuit production line, the target support position moves 5 mm within 0.2 seconds of the filling material falling due to changes in production line speed. First, this 5 mm movement distance is calculated based on real-time acceleration and the falling time of the filling material. Then, using a preset mechanical transmission ratio, for example, each millimeter of linear movement corresponds to a 0.1 degree phase angle of the servo motor, this 5 mm movement distance is converted into a 0.5 degree phase offset of the servo actuator. At the start of the next control cycle, this 0.5 degree phase offset is dynamically added to the phase register of the servo actuator. This means that the motion command of the servo actuator is executed 0.5 degrees of phase angle in advance, thus physically canceling out the 5 mm forward movement of the target support position. Therefore, when the filling material falls to the target support position, the new product on the support position is precisely below the preset initial landing point of the filling material, ensuring accurate support of the filling material.

[0051] This application further proposes the following steps for comparing the expected landing point with the landing point boundary, and adjusting the sandwich cutoff trigger timing in the next control cycle based on the comparison results: Calculate the physical distance between the expected landing point and the landing point boundary; Obtain the real-time speed of the cookie production line and convert the physical distance into landing point tolerance time based on the real-time speed; If the error tolerance time is less than the preset critical threshold, the sandwich cut-off trigger timing in the next control cycle will be adjusted; otherwise, the current sandwich cut-off trigger timing will be maintained.

[0052] Specifically, calculating the physical distance between the expected landing point and the landing point boundary means that, after determining the expected landing point of the sandwich material on the new product supported by the target bearing position, and after calculating the allowable landing point boundary of the sandwich material on a single bearing position, the actual spatial deviation between the expected landing point and the landing point boundary is quantified by subtraction or other geometric calculation methods. This physical distance can be understood as the distance between the actual landing point of the sandwich material and the edge of the ideal landing point range.

[0053] The process of acquiring the real-time speed of the biscuit production line and converting physical distance into landing point tolerance time based on this speed aims to transform spatial deviations into temporal margins, thereby providing a more intuitive assessment of the impact of current deviations on the production process. Real-time speed refers to the instantaneous operating speed of the biscuit production line during the descent of the filling material within the current control cycle. Landing point tolerance time can be understood as the maximum allowable time deviation between the expected landing point position of the filling material and the landing point boundary at the current production speed.

[0054] In practical applications, if the landing error tolerance time is less than the preset critical threshold, the sandwich cutting trigger timing for the next control cycle will be adjusted; otherwise, the current sandwich cutting trigger timing will be maintained. The preset critical threshold is an empirical value or a safety margin set according to process requirements, used to determine whether the current landing error has reached a level requiring intervention. When the landing error tolerance time is less than this threshold, it indicates that the landing error of the sandwich material has approached or exceeded the acceptable range, requiring immediate adjustment to avoid product defects. Conversely, if the landing error tolerance time is greater than or equal to the critical threshold, the current deviation is considered to be within the acceptable range, and no adjustment is required.

[0055] In some preferred embodiments, it is assumed that within a certain control cycle, the expected landing position of the sandwich material is calculated as X_expected, and the landing boundary is X_boundary. In this case, the physical distance ΔX between the two is first calculated as |X_expected - X_boundary|. For example, if X_expected = 105 mm and X_boundary = 100 mm, then the physical distance ΔX = 5 mm.

[0056] Next, obtain the real-time speed of the biscuit production line. Assume the current real-time speed is V_real = 0.5 m / s. Based on this real-time speed, convert the physical distance ΔX into the landing point tolerance time ΔT = ΔX / V_real = 0.005 m / 0.5 m / s = 0.01 s.

[0057] Subsequently, the calculated landing point tolerance time ΔT is compared with the preset critical threshold T_threshold, assuming that the preset critical threshold T_threshold is 0.008s.

[0058] Since the calculated landing point tolerance time ΔT is greater than the preset critical threshold T_threshold, this indicates that although the current landing point deviation exists, it is still within an acceptable time margin and has not yet reached a level requiring immediate intervention. Therefore, the current sandwich cutoff trigger timing is maintained without adjustment.

[0059] Conversely, in another scenario, if the calculated landing point tolerance time ΔT is 0.006s, and ΔT is less than T_threshold, then it is determined that the landing point deviation has exceeded the safety margin. It is necessary to trigger and adjust the sandwich cutting trigger timing in the next control cycle to correct the deviation and ensure the accurate landing point of the sandwich material.

[0060] This application further proposes a step for triggering and adjusting the sandwich cutoff trigger timing in the next control cycle, including: Calculate the rate of change of the distance between the expected landing point and the landing point boundary over time; Based on the rate of change, calculate the global time advance before the start of the next control cycle; Based on the global time advance, the sandwich cut-off trigger timing in the next control cycle is reconstructed.

[0061] Specifically, calculating the rate of change of the distance between the expected landing point and the landing point boundary over time refers to determining the dynamic trend of this distance by monitoring the change of the physical distance between the expected landing point and the landing point boundary within a continuous control cycle. This rate of change reflects the degree of deviation and the trend of change between the actual landing point and the ideal landing point area of ​​the filling material under the current operating state of the biscuit production line, and its purpose is to provide a dynamic basis for subsequent precise adjustments.

[0062] Specifically, based on the rate of change, a global time advance is calculated before the start of the next control cycle. This can be understood as predicting, based on the calculated rate of distance change, how much time adjustment is needed to advance or lag the sandwich cutting action within the next control cycle. This global time advance is a comprehensive adjustment parameter designed to achieve precise control of the sandwich material's landing point by fine-tuning the time axis of the entire control cycle.

[0063] In a cookie production line, there may be a distance deviation between the expected landing point of a sandwich cookie and the preset landing point boundary. The rate of change indicates how quickly and in what direction this distance deviation changes over time. If the rate of change is positive, it may mean that the actual landing point of the cookie is continuously moving forward or backward relative to the ideal boundary, depending on the coordinate system definition drift, causing the deviation to gradually increase. If the rate of change is negative, it may mean that the deviation is decreasing or drifting in the opposite direction. This rate of change reflects the current dynamic trend and is an important basis for predicting future deviations.

[0064] To calculate the rate of change of distance over time, it is first necessary to obtain the distance between the expected landing position and the landing boundary at different time points. The expected landing position is acquired in real-time or periodically at different time points within a continuous control cycle or at different times within the current control cycle. By comparing the expected landing position with the landing boundary, the instantaneous distance between them can be calculated. For example, if the landing boundary is a center point, the distance is the deviation of the expected landing position from that center point; if the landing boundary is a range, the distance can be the distance between the expected landing position and the nearest edge of that range.

[0065] Suppose the distance measured at time point t1 is D1, and the distance measured at the next time point t2 is D2. In practical applications, the difference approximation method is usually used for calculation. That is, the rate of change can be approximated as: Rate of change V = (D2 - D1) / (t2 - t1). This calculation result represents how much the average distance between the expected landing point and the landing point boundary changes per unit time during the time interval (t2 - t1). A positive value may indicate that the distance is increasing and deviating from the target, while a negative value may indicate that the distance is decreasing and approaching the target.

[0066] Since we have calculated the rate of change V of the distance between the expected landing point and the landing point boundary over time, typically expressed as distance / time (e.g., millimeters / second), we can use this rate to predict how much the positional deviation will accumulate over a specific future time period. This future time period is usually called the prediction window or look-ahead time, denoted as T_predict. T_predict can be the duration of the next control cycle or the time required for the biscuit to travel from the current detection point to the cutting mechanism.

[0067] Therefore, the expected additional positional deviation ΔD_predicted within the time interval T_predict can be calculated using the following formula: ΔD_predicted = V × T_predict The ΔD_predicted value represents the distance by which the biscuit's landing position will deviate further from the ideal boundary after a time interval T_predict, without any adjustments. To compensate for this predicted ΔD_predicted positional deviation, the timing of the sandwich cutting trigger needs to be adjusted accordingly. This adjustment is the global timing advance, denoted as T_advance. To convert the positional deviation into a timing adjustment, the linear velocity of the biscuit at the cutting mechanism, denoted as S_biscuit, is needed, typically expressed as distance / time, such as millimeters per second.

[0068] Therefore, the global time advance T_advance can be calculated using the following formula: T_advance=ΔD_predicted / S_biscuit Substituting the expression for ΔD_predicted, we obtain the final calculation formula: T_advance=(V×T_predict) / S_biscuit In practical applications, the sign of T_advance indicates whether the cutting timing needs to be advanced or delayed. For example, if V is positive, indicating that the cookie landing point continues to drift forward, the calculated T_advance may also be positive, meaning that the trigger timing for sandwich cutting needs to be advanced accordingly so that the cookie is cut when it reaches the correct position. Conversely, if V is negative, the trigger timing may need to be delayed. Using this method, based on the current trend of positional deviation changes, the global time advance can be calculated before the start of the next control cycle, thereby achieving precise synchronous control of the sandwich cutting timing in the cookie production line.

[0069] In practical applications, the sandwich cut-off trigger timing in the next control cycle is reconstructed based on the global time advance. Specifically, this means adjusting the trigger time of the sandwich cut-off in the next control cycle based on the calculated global time advance.

[0070] In some preferred embodiments, it is assumed that during a certain control cycle, the expected landing point is detected moving outward from the landing point boundary at a rate of 0.5 mm per second. Based on this rate of change, it can be predicted that in the next control cycle, if the sandwich cutting trigger timing is not adjusted, the sandwich material will deviate further from the ideal landing point. Therefore, before the start of the next control cycle, for example, a global timing advance of 10 milliseconds is calculated. Subsequently, based on this 10-millisecond global timing advance, the motion trajectory or phase angle of the servo actuator in the next control cycle is replanned, so that the sandwich cutting action is triggered at a new time point, thereby effectively pulling the landing point of the sandwich material back to the expected landing point area. This dynamic and forward-looking adjustment ensures that even when the speed or acceleration of the biscuit production line changes, the sandwich material can accurately land in the preset position of the new product.

[0071] Furthermore, the steps for converting physical distance into landing point tolerance time based on real-time velocity include: When the absolute value of the real-time acceleration is less than the preset dead zone threshold, the physical distance is divided by the real-time velocity to obtain the landing point tolerance time. When the real-time acceleration is greater than or equal to the preset dead zone threshold, the landing point tolerance time is calculated based on the uniform acceleration motion formula, using physical distance, real-time velocity, and real-time acceleration.

[0072] Specifically, the preset dead zone threshold can be understood as a critical value used to determine whether the biscuit production line is in a state of significant acceleration or deceleration. When the absolute value of the real-time acceleration is below this threshold, it indicates that the production line speed is relatively stable, or the impact of acceleration on the motion trajectory is negligible. In this case, the landing point tolerance time is calculated using a simplified uniform motion model, which is obtained directly by dividing the physical distance by the real-time speed. This method is computationally efficient and provides sufficient accuracy under stable operating conditions. However, when the absolute value of the real-time acceleration reaches or exceeds the preset dead zone threshold, the biscuit production line is considered to be undergoing a significant acceleration or deceleration process. At this time, to ensure the accuracy of the calculation, a more complex uniform acceleration motion formula is required.

[0073] This application addresses the limitations of relying solely on real-time speed for landing point tolerance time conversion under dynamic operating conditions by introducing a judgment of real-time acceleration. Specifically, when the absolute value of real-time acceleration is small, i.e., less than the preset dead zone threshold, the production line is determined to be in a relatively stable operating state. In this case, a simplified uniform speed model is used for calculation, ensuring real-time performance and efficiency. When the absolute value of real-time acceleration is large, i.e., greater than or equal to the preset dead zone threshold, the calculation switches to a uniform acceleration motion formula, fully considering the impact of speed changes on travel time. This adaptive calculation strategy ensures that the landing point tolerance time can be accurately calculated under different operating conditions such as acceleration, deceleration, or uniform speed operation of the biscuit production line, providing a reliable time basis for subsequent sandwich cutting trigger timing adjustment.

[0074] Through the above technical solution, this application can significantly improve the accuracy of the landing point tolerance time calculation, especially under dynamic operating conditions where the speed and acceleration of the production line frequently change during product batch changeovers in a biscuit production line. By adaptively selecting a uniform speed or uniform acceleration motion model for calculation based on the absolute value of real-time acceleration, calculation errors caused by simply assuming uniform speed motion during acceleration or deceleration are avoided. Therefore, the tolerance time corresponding to the physical distance between the expected landing point position of the filling material and the landing point boundary can be more accurately assessed, making the adjustment of the filling cutting trigger timing more timely and precise, effectively reducing material waste, improving product qualification rate, and enhancing the operational stability of the production line.

[0075] In some preferred embodiments, it is assumed that the biscuit production line needs to smoothly transition from one speed to another when changing product batches. Within a certain control cycle, the real-time acceleration, real-time speed, and physical distance between the expected landing point and the landing point boundary of the biscuit production line are first acquired. Specifically, if the absolute value of the real-time acceleration is 0.08 m / s², ... 2 The preset dead zone threshold is 0.1 m / s. 2 Due to 0.08m / s 2Less than 0.1 m / s 2 This will determine that the current production line is in a relatively stable state. In this case, if the physical distance is 0.03 meters and the real-time speed is 0.6 m / s, the landing point tolerance time will be calculated as 0.03 meters / 0.6 m / s = 0.05 seconds. On the other hand, if the production line is undergoing rapid acceleration, the absolute value of the real-time acceleration is 0.2 m / s². 2 , greater than or equal to the preset dead zone threshold of 0.1 m / s 2 In this case, the formula for uniformly accelerated motion will be used for calculation. For example, if the physical distance is still 0.03 meters, the real-time velocity is 0.6 m / s, and the real-time acceleration is 0.2 m / s². 2 Then, according to the formula for uniformly accelerated motion, s = v0 * t + 0.5 * a * t^2 (where s is the physical distance, v0 is the real-time velocity, a is the real-time acceleration, and t is the landing error tolerance time), solving this quadratic equation can yield a more accurate landing error tolerance time. For example, the calculated result might be 0.048 seconds.

[0076] This application further proposes that after calculating the landing point tolerance time based on the uniform acceleration motion formula using physical distance, real-time velocity, and real-time acceleration, if the landing point tolerance time calculated based on the uniform acceleration motion formula using physical distance, real-time velocity, and real-time acceleration is less than zero, then it is determined that there is a conflict in the input data, the landing point tolerance time is forcibly set to zero, and an out-of-bounds warning is output; otherwise, the calculated landing point tolerance time is directly adopted.

[0077] Among these, determining an input data conflict means that, based on the current physical distance, real-time velocity, and real-time acceleration, a physically reasonable positive time cannot be obtained. This may indicate abnormal sensor data, incorrect model assumptions, or system states exceeding expectations. Forcing the landing point tolerance time to zero is a fault-tolerant mechanism designed to avoid negative time values ​​negatively impacting subsequent control logic. Setting it to zero means immediate adjustment will be triggered, responding to potential anomalies in the most conservative way. Output out-of-bounds warnings issue alerts to the operator or the higher-level control system, indicating potential data problems or system anomalies, allowing for timely manual intervention or troubleshooting.

[0078] This application addresses the issue of negative landing point tolerance time under extreme or abnormal data input conditions by adding a validity judgment and correction mechanism after calculating the tolerance time. When the landing point tolerance time calculated based on the uniform acceleration motion formula is less than zero, it indicates that there may be conflicts or anomalies in the current physical distance, real-time velocity, and real-time acceleration data. Directly using this negative value will lead to confusion in the control logic. By forcibly setting the landing point tolerance time to zero and outputting an out-of-bounds warning, erroneous control commands caused by invalid data can be avoided.

[0079] Through the above technical solution, this application can effectively handle the situation where the calculated landing point tolerance time is negative due to data anomalies or extreme operating conditions during the synchronous control of a biscuit production line. This handling mechanism avoids the interference of negative time values ​​on subsequent control decisions. When data conflicts occur, it can promptly perform fault tolerance processing, forcibly setting the landing point tolerance time to zero and issuing an out-of-bounds warning, thereby effectively preventing control errors caused by abnormal data and ensuring the stable operation of the production line and the stability of product quality.

[0080] As a specific implementation method, assume that during the operation of the biscuit production line, the real-time acceleration is -5 m / s² (i.e., deceleration), the real-time speed is 2 m / s, and the physical distance is 0.1 m. If the uniform acceleration motion formula d = v0*t + 0.5*a*t^2 is directly applied to solve for time t, a negative solution or no real solution may be obtained. In some cases, even if a positive solution is obtained, the result may be slightly less than zero due to calculation errors. For example, in a certain calculation instance, the landing point tolerance time calculated by the formula is -0.05 seconds. According to this implementation method, since the calculated landing point tolerance time of -0.05 seconds is less than zero, it is determined that there is a conflict in the input data. At this time, the landing point tolerance time is forcibly set to zero, and a landing point tolerance time out-of-bounds warning is output to the console. In this way, the subsequent control logic will be processed based on the landing point tolerance time being zero, that is, the sandwich cutting trigger timing in the next control cycle will be immediately triggered and adjusted, thereby avoiding unpredictable control behavior caused by negative time values ​​and ensuring the safe and stable operation of the production line.

[0081] This application further proposes steps for reconstructing the sandwich cutoff trigger timing in the next control cycle based on global timing advance, including: Based on the global timing advance and the angular velocity of the servo actuator of the biscuit production line, the global timing advance is converted into the phase angle advance of the sandwich cutting trigger in the next control cycle; Extract the phase angle of the servo actuator at the end of the current control cycle as the first constraint condition; Add the phase angle of the servo actuator at the end of the current control cycle to the phase angle forward shift to obtain the target phase angle as the second constraint condition; Based on the polynomial spline interpolation algorithm, a smooth transition curve is planned with time as the horizontal axis and the phase angle of the servo actuator as the vertical axis, so that the phase angle smoothly transitions from the first constraint condition to the second constraint condition. The smooth transition curve is discretized and sent to the servo actuator so that the sandwich cut-off trigger time of the next control cycle is advanced accordingly.

[0082] Specifically, global timing advance refers to the overall time adjustment required to correct the deviation between the expected landing position and the landing boundary of the sandwich material before the start of the next control cycle. The angular velocity of the servo actuator in a biscuit production line refers to the rotational speed of the servo motor or related actuators driving the biscuit production line, typically expressed in radians per second or degrees per second. Converting global timing advance into phase angle advance aims to map the time-domain adjustment to the rotational angle domain of the servo actuator, facilitating precise control by the servo system.

[0083] The first constraint condition is to extract the phase angle of the servo actuator at the end of the current control cycle. Its purpose is to obtain the starting point of the current motion state and ensure the continuity of the transition. The second constraint condition is to add the phase angle of the servo actuator at the end of the current control cycle to the phase angle forward shift, obtaining the target phase angle. Its purpose is to determine the target state that the servo actuator should reach at the end of the next control cycle after adjustment.

[0084] In practical applications, the polynomial spline interpolation algorithm can generate high-order continuous curves, effectively avoiding shocks and vibrations during motion. After discretizing the smooth transition curve, it is sent to the servo actuator, that is, the continuous motion trajectory is transformed into a discrete instruction sequence that the servo controller can execute. This allows the sandwich cut-off trigger time of the next control cycle to be advanced accordingly, and the transition is achieved in a smooth manner.

[0085] This application constructs the start and end points of the servo actuator's motion trajectory by converting the global timing advance into the phase angle advance of the servo actuator, and combining the phase angle at the end of the current control cycle as the first constraint and the target phase angle as the second constraint. It is precisely because of the use of a polynomial spline interpolation algorithm that a smooth transition curve can be planned between the two constraints. The generation of this smooth transition curve effectively avoids mechanical shocks and vibrations that may occur when adjusting the sandwich cutting trigger timing, thus ensuring the operational stability of the biscuit production line during the transition period. By distributing the discretized smooth transition curve to the servo actuator, the sandwich cutting trigger time can be advanced in a controlled and stable manner, thereby accurately adjusting the landing point position while avoiding wear on the production line's mechanical components and impacting product quality.

[0086] Through the above technical solution, this application can achieve smooth and precise adjustment of the sandwich cutting trigger timing. Compared with directly adjusting the timing advance, using a polynomial spline interpolation algorithm to plan the phase angle transition curve of the servo actuator significantly improves the operational stability of the production line during product batch changeovers, effectively avoiding problems such as mechanical shock, vibration, and inaccurate product landing points caused by sudden timing changes. This not only extends the service life of the equipment and reduces maintenance costs, but more importantly, it ensures the accuracy of the sandwich material landing point and the stability of product quality under high-speed production conditions, thereby improving the automation level and production efficiency of the entire biscuit production line.

[0087] In some preferred embodiments, it is assumed that a global timing lead of 50 milliseconds is required within a certain control cycle to correct for the landing point deviation of the filling material. At this time, the angular velocity of the servo actuator of the biscuit production line is 100 degrees / second.

[0088] First, based on the global timing advance of 50 milliseconds and the angular velocity of the servo actuator of 100 degrees / second, the timing advance is converted into a phase angle shift. For example, a timing advance of 50 milliseconds corresponds to a phase angle shift of 5 degrees, 50ms * 100 degrees / s = 5 degrees.

[0089] Next, the phase angle of the servo actuator at the end of the current control cycle is extracted, for example, 180 degrees, and used as the first constraint condition.

[0090] Then, the current phase angle of 180 degrees is added to the calculated phase angle forward shift of 5 degrees to obtain the target phase angle of 185 degrees, which is used as the second constraint condition.

[0091] Subsequently, based on the polynomial spline interpolation algorithm, a curve is planned with time as the horizontal axis and the phase angle of the servo actuator as the vertical axis, smoothly transitioning from 180 degrees to 185 degrees. This ensures that the servo actuator can smoothly transition from the current state to the target state at the beginning of the next control cycle.

[0092] Finally, this smooth transition curve is discretized into a series of servo commands and sent to the servo actuator. The servo actuator drives the conveyor belt to run flexibly along the smooth transition curve. When the conveyor belt spindle rotates to the preset trigger phase angle, the sandwich cutting action is triggered. In this way, the trigger time of the sandwich cutting in the next control cycle will be advanced accordingly, and the entire adjustment process is smooth and shock-free, thus ensuring the accurate landing point of the sandwich material and the stable operation of the production line.

[0093] Secondly, see Figure 2 This application also proposes a synchronous control system for a biscuit production line, used to execute the synchronous control method for a biscuit production line as described above, the system comprising: The parameter acquisition module 210 is used to acquire the real-time acceleration of the biscuit production line, the preset specification parameters of the new product, and the falling time of the filling material; The expected landing position generation module 220 is used to calculate the moving distance of the target bearing position within the falling time of the sandwich material based on the real-time acceleration and the falling time of the sandwich material, and determine the expected landing position of the sandwich material on the new product supported by the target bearing position according to the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target bearing position. The landing point boundary calculation module 230 is used to calculate the landing point boundary of the sandwich material according to the preset specification parameters of the new product. The control module 240 is used to compare the expected landing point position with the landing point boundary, and adjust the sandwich cut-off trigger timing in the next control cycle according to the comparison result.

[0094] By using a modular architecture design, the complex synchronous control logic is decoupled into independent functional units. The modules interact with each other through standard interfaces, which not only ensures the integrity of the control logic, but also facilitates flexible configuration and hardware deployment according to the scale of the production line.

[0095] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A biscuit production line synchronization control method for execution during a changeover transition of different size product batches, characterized by, The method includes: The system acquires real-time acceleration data of the biscuit production line, preset specifications of new products, and the time taken for filling materials to fall. Based on the real-time acceleration and the falling time of the sandwich material, the moving distance of the target support position during the falling time of the sandwich material is calculated. According to the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target support position, the expected landing position of the sandwich material on the new product supported by the target support position is determined. The landing point boundary of the sandwich material is calculated based on the preset specification parameters of the new product; The expected landing point position is compared with the landing point boundary, and the sandwich cut-off trigger timing is adjusted in the next control cycle based on the comparison result.

2. The synchronous control method for a biscuit production line according to claim 1, characterized in that, The step of calculating the movement distance of the target bearing position within the falling time of the sandwich material based on the real-time acceleration and the falling time of the sandwich material includes: During the falling process of the filling material, the moment of filling cutting is taken as the starting point of integration, and the time from the moment of filling cutting to the end of the falling time of the filling material is taken as the integration interval. Combined with the real-time speed of the biscuit production line at the integration starting point, the real-time acceleration is integrated twice to calculate the moving distance of the target bearing position.

3. The synchronous control method for a biscuit production line according to claim 1, characterized in that, The step of calculating the landing point boundary of the sandwich material based on the preset specification parameters of the new product includes: Obtain the allowable process offset for the new product; Based on the preset specification parameters and the allowable offset of the process, the boundary of the allowable landing point of the sandwich material on a single bearing position is calculated.

4. The synchronous control method for a biscuit production line according to claim 1, characterized in that, After determining the expected landing position of the sandwich material on the new product supported by the target bearing position based on the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target bearing position, the process includes: The moving distance is converted into the phase offset of the servo actuator of the biscuit production line by the mechanical transmission ratio; Between each control cycle, the phase offset is dynamically superimposed on the phase register of the servo actuator to offset the movement distance of the target bearing position.

5. The synchronous control method for a biscuit production line according to claim 1, characterized in that, The step of comparing the expected landing point position with the landing point boundary and adjusting the sandwich cutoff trigger timing in the next control cycle based on the comparison result includes: Calculate the physical distance between the expected landing point location and the landing point boundary; The real-time speed of the biscuit production line is obtained, and the physical distance is converted into a landing point tolerance time based on the real-time speed. If the fault tolerance time of the landing point is less than the preset critical threshold, the sandwich cutting trigger timing in the next control cycle will be adjusted; otherwise, the current sandwich cutting trigger timing will be maintained.

6. The synchronous control method for a biscuit production line according to claim 5, characterized in that, The step of triggering and adjusting the sandwich cutoff trigger timing in the next control cycle includes: Calculate the rate of change of the distance between the expected landing point and the landing point boundary over time; Based on the rate of change, the global timing advance is calculated before the start of the next control cycle. Based on the global time advance, the sandwich cutoff trigger timing in the next control cycle is reconstructed.

7. The synchronous control method for a biscuit production line according to claim 5, characterized in that, The step of converting the physical distance into landing point tolerance time based on the real-time speed includes: When the absolute value of the real-time acceleration is less than the preset dead zone threshold, the physical distance is divided by the real-time velocity to obtain the landing point tolerance time. When the real-time acceleration is greater than or equal to the preset dead zone threshold, the landing point tolerance time is calculated based on the uniform acceleration motion formula using the physical distance, the real-time velocity, and the real-time acceleration.

8. The synchronous control method for a biscuit production line according to claim 7, characterized in that, The step of calculating the landing point tolerance time based on the uniformly accelerated motion formula using the physical distance, the real-time velocity, and the real-time acceleration includes the following: If the calculated landing point tolerance time, based on the uniform acceleration motion formula and using the physical distance, real-time velocity, and real-time acceleration, is less than zero, then it is determined that there is a conflict in the input data, the landing point tolerance time is forcibly set to zero, and an out-of-bounds warning is output; otherwise, the calculated landing point tolerance time is directly used.

9. A synchronous control method for a biscuit production line according to claim 6, characterized in that, The step of reconstructing the sandwich cutoff trigger timing sequence within the next control cycle based on the global timing advance includes: Based on the global timing advance and the angular velocity of the servo actuator of the biscuit production line, the global timing advance is converted into the phase angle advance of the sandwich cutting trigger in the next control cycle; Extract the phase angle of the servo actuator at the end of the current control cycle as the first constraint condition; The phase angle of the servo actuator at the end of the current control cycle is added to the phase angle forward shift to obtain the target phase angle as the second constraint condition; Based on the polynomial spline interpolation algorithm, a smooth transition curve is planned with time as the horizontal axis and the phase angle of the servo actuator as the vertical axis, so that the phase angle smoothly transitions from the first constraint condition to the second constraint condition. The smooth transition curve is discretized and sent to the servo actuator so that the sandwich cutoff trigger time of the next control cycle is advanced accordingly.

10. A synchronous control system for a biscuit production line, used to execute the synchronous control method for a biscuit production line as described in any one of claims 1 to 9, characterized in that, The system includes: The parameter acquisition module is used to acquire the real-time acceleration of the biscuit production line, the preset specifications of new products, and the falling time of the filling material; The expected landing position generation module is used to calculate the moving distance of the target support position within the falling time of the sandwich material based on the real-time acceleration and the falling time of the sandwich material, and determine the expected landing position of the sandwich material on the new product supported by the target support position according to the moving distance and the preset initial landing position of the sandwich material on the new product supported by the target support position. The landing point boundary calculation module is used to calculate the landing point boundary of the sandwich material according to the preset specification parameters of the new product. The control module is used to compare the expected landing point position with the landing point boundary, and adjust the sandwich cut-off trigger timing in the next control cycle according to the comparison result.

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