A method and apparatus for the automatic continuous extrusion of rubber-based soft gaskets

Abstract

The application discloses a kind of automatic continuous extrusion rubber-based soft packing production method and device, the Mooney viscosity data of rubber-based rubber material and the wall temperature distribution data of barrel are collected, and viscosity-temperature consistency index is generated by implementing correlation verification;Carry out temperature difference distribution evaluation to generate segmented plasticizing progress distribution, determine the plasticizing insufficient section to construct segmented plasticizing process scheme in combination with temperature difference gradient between segments;Evaluate viscosity deviation distribution, generate heat compensation scheme by cross-section heat surplus redistribution, implement heat directional compensation to establish segmented control threshold;Execute barrel temperature and screw speed adjustment to generate process adjustment record, verify head back pressure fluctuation to confirm back pressure steady section to generate plasticizing uniform value;Back-propagation head choke block throttling gap generates choke block throttling gap adjustment scheme, executes head pressure regulation and outputs extrusion molding control instruction, realizes the plasticizing state on-line diagnosis and head pressure closed-loop control of waste rubber-plastic reclaimed rubber material extrusion molding.

Description

Technical Field

[0001] This invention relates to the field of rubber and plastic material recycling technology, and in particular to an automatic continuous extrusion method and apparatus for producing rubber-based soft liners. Background Technology

[0002] In the recycling of waste plastics, core equipment in sorting, conveying, crushing, grinding, and compression granulation processes generally requires rubber-based soft liners as inner wall protection and buffering media. These soft liners must maintain dimensional stability and surface uniformity over long periods under high-frequency impact and complex temperature environments, demanding high consistency in the heating and flow uniformity of the rubber compound during production. Current soft liner production commonly employs an experience-based screw extrusion process, relying on operators' experience to determine heating zone temperature settings and screw speed ratios. The lack of systematic correlation verification methods for process parameters between batches makes it difficult to maintain consistent heating and flow of the rubber compound across different functional sections of the screw throughout the entire process. This results in batch-to-batch fluctuations in product cross-sectional density distribution and wall thickness uniformity, directly impacting the service life of the soft liners in recycling equipment.

[0003] To address the aforementioned issues, existing improvement solutions primarily focus on localized optimization of single process stages, such as adjusting the power of the barrel heating zones individually or controlling the screw speed independently. These solutions lack cross-stage linkage mechanisms between adjustment parameters, and the adjustment effects are difficult to reproduce stably due to batch-to-batch viscosity differences in the rubber compound formulation. Furthermore, the impact of dynamic fluctuations in die head back pressure on extrusion uniformity is not effectively monitored in existing solutions. Adjustments to the die head flow obstruction structure still rely on manual operation during shutdown, failing to respond in real-time to changes in the rubber compound flow state during continuous production, further limiting the stability of the soft liner extrusion molding quality. Summary of the Invention

[0004] This invention discloses an automatic continuous extrusion method and apparatus for producing rubber-based soft liners. By implementing online correlation evaluation of the viscosity-temperature consistency of waste rubber and plastic recycled materials and the segmented plasticizing progress, combined with the redistribution of cross-segment heat margin and the establishment of segmented control thresholds, dynamic equilibrium control of the screw's plasticizing state throughout the entire process is achieved. Based on the back pressure stabilization judgment and the automatic back-pushing of the throttling gap of the die head choke block, extrusion molding control commands are output during continuous extrusion to ensure the cross-sectional uniformity and dimensional stability of the rubber-based soft liners.

[0005] The first aspect of this invention provides an automated continuous extrusion method for producing rubber-based soft liners, comprising the following steps: Collect Mooney viscosity data of the rubber-based compound to be extruded and barrel wall temperature distribution data, and perform correlation verification on the Mooney viscosity data and the wall temperature distribution data to generate viscosity-temperature consistency index; The wall temperature distribution data is used to evaluate the temperature difference distribution and generate a segmented plasticizing progress distribution. The temperature difference along the axial direction of the feeding section, compression section and homogenization section is measured from the wall temperature distribution data to generate the inter-segment temperature difference gradient. Based on the segmented plasticizing progress distribution and the inter-segment temperature difference gradient, the insufficient plasticizing section is determined and a segmented plasticizing process scheme is constructed. Based on the viscosity-temperature consistency index and the segmented plasticizing process scheme, a segmented viscosity deviation assessment is carried out to generate a viscosity deviation distribution. The viscosity deviation distribution is then redistributed across segments to generate a heat compensation scheme. Based on the heat compensation scheme, heat-oriented compensation is implemented to establish segmented control thresholds. Based on the segmented control threshold, the barrel temperature and screw speed are adjusted according to the segmented plasticizing process scheme to generate process adjustment records. Based on the process adjustment records, the back pressure fluctuation of the die head is verified to generate back pressure fluctuation data. Through the back pressure fluctuation data, the back pressure stabilization zone is confirmed to generate a plasticizing uniformity value. Based on the plasticizing uniformity value, the flow obstruction block throttling gap of the die head is reversed to generate a flow obstruction block throttling gap adjustment scheme. According to the flow obstruction block throttling gap adjustment scheme, the die head pressure is adjusted and the extrusion molding control command is output.

[0006] A second aspect of the present invention provides an automatic continuous extrusion rubber-based soft liner production apparatus, comprising: The data acquisition unit is used to collect Mooney viscosity data and barrel wall temperature distribution data of the rubber-based compound to be extruded, and to perform correlation verification on the Mooney viscosity data and the wall temperature distribution data to generate a viscosity-temperature consistency index. The plasticizing assessment unit is used to evaluate the temperature difference distribution of the wall temperature distribution data to generate a segmented plasticizing progress distribution, measure the axial temperature difference between the feeding section, compression section and homogenization section from the wall temperature distribution data to generate the inter-segment temperature difference gradient, and determine the insufficient plasticizing section based on the segmented plasticizing progress distribution and the inter-segment temperature difference gradient to construct a segmented plasticizing process scheme. The compensation decision unit is used to conduct segmented viscosity deviation assessment based on the viscosity-temperature consistency index and the segmented plasticizing process scheme to generate a viscosity deviation distribution, redistribute the cross-segment heat margin of the viscosity deviation distribution to generate a heat compensation scheme, and implement heat-oriented compensation based on the heat compensation scheme to establish segmented control thresholds. The extrusion control unit is used to adjust the barrel temperature and screw speed according to the segmented control threshold to generate a process control record for the segmented plasticizing process scheme, verify the back pressure fluctuation of the die head based on the process control record to generate back pressure fluctuation data, and confirm the back pressure stabilization zone through the back pressure fluctuation data to generate a plasticizing uniform value. The molding output unit is used to generate a throttling gap adjustment scheme for the throttling gap of the die head based on the plasticizing uniformity value, and to execute the die head pressure adjustment and output extrusion molding control command according to the throttling gap adjustment scheme.

[0007] The beneficial effects of this invention are reflected in the following points: First, by collecting data on the viscosity characteristics of the rubber compound and the temperature response data of each section of the barrel and implementing segment-by-segment correlation verification, mismatched sections with large viscosity-temperature timing coupling deviations are identified. Combined with the temperature gradient distribution and flow state assessment of each functional section, sections with insufficient plasticization are accurately located, and segmented plasticization process schemes are constructed accordingly. This achieves full-process diagnosis from the state of the rubber compound feed to the plasticization progress of each functional section of the screw, shifting the process adjustment target from vague experience-based judgment to verifiable quantitative positioning. Second, by jointly analyzing the viscosity deviation level and heat reserve of each functional section, a cross-segment heat compensation demand matching relationship is established. The cross-segment redistribution of screw shear heat is used to compensate for the energy deficit in the heat gap section. Furthermore, a unit heat temperature rise decay analysis is performed on the sections where overheating rebound occurs during compensation execution. The upper limit of the compensation heat for each section is established with the inflection point of decreasing conduction efficiency as the boundary, forming a segmented control threshold with safety constraints, achieving a dynamic balance between compensation effectiveness and overheat prevention. Finally, based on the segmented control threshold, the screw speed and barrel temperature are directionally adjusted. By extracting the spontaneous back pressure fluctuation data during the constant speed period, the residual fluctuation curve is extracted to identify the homogenization process segment where the fluctuation amplitude continues to narrow. Combined with the trend of the change in the proportion of back pressure fluctuation types, the back pressure stabilization segment is confirmed and the steady-state duration is verified. The plasticization uniformity value is evaluated in a weighted manner, and then the die head throttling block throttling gap adjustment scheme is deduced and the die head pressure is adjusted. The evaluation of the plasticization state in the continuous extrusion process and the die head pressure control form a closed-loop response, which improves the cross-sectional uniformity and batch stability of the rubber-based soft liner molding process. Attached Figure Description

[0008] Figure 1 This is a schematic flowchart of an automatic continuous extrusion method for producing rubber-based soft liners according to the present invention.

[0009] Figure 2 This is a schematic diagram of the overall structure and sensor arrangement of the extrusion device of the present invention.

[0010] Figure 3 This is a structural block diagram of an automatic continuous extrusion rubber-based soft liner production device according to the present invention.

[0011] Wherein: 1-Barrel; 2-Screw; 3-Feeding section; 4-Compression section; 5-Homogenization section; 6-Thermocouple measuring point in feeding section; 7-Thermocouple measuring point in compression section; 8-Thermocouple measuring point in homogenization section; 9-Mounney viscometer mounting position; 10-Extrusion section; 11-Pressure sensor array; 12-Die head; 13-Baffle block; 14-Servo drive mechanism; 15-Displacement sensor; 16-Die head inlet pressure sensor; 17-Die. Detailed Implementation

[0012] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, circuits, and methods are omitted so as not to obscure the description of this application with unnecessary detail.

[0013] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0014] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0015] The technical solutions of the embodiments of this application will be described below.

[0016] like Figure 1 As shown, this embodiment of the invention provides an automated continuous extrusion method for producing rubber-based soft liners, including the following steps S11-S15: Step S11: Collect Mooney viscosity data of the rubber-based compound to be extruded and barrel wall temperature distribution data, and perform correlation verification on the Mooney viscosity data and wall temperature distribution data to generate viscosity-temperature consistency index.

[0017] Specifically, Mooney viscosity data of the rubber-based compound to be extruded and barrel wall temperature distribution data are collected. For example... Figure 2As shown, Mooney viscosity data is measured online in the extrusion section 10 before the rubber compound enters the barrel 1 using a Mooney viscometer installed at position 9. The measuring rotor is an L-shaped large rotor. The test temperature is determined based on the nominal viscosity range of the rubber compound formulation for this batch. Mooney viscosity data is collected once per reference speed cycle of each screw 2. The reference speed cycle is calculated from the rated speed of screw 2 and the axial advance per revolution. The collection frequency is synchronized with the actual conveying rhythm of the rubber compound. Barrel 1 wall temperature distribution data is collected by a thermocouple array evenly distributed along the axial direction of barrel 1. Thermocouple measuring points 6 in the feeding section, 7 in the compression section, and 8 in the homogenization section are respectively located in the feeding section 3, compression section 4, and homogenization section 5. The distance between adjacent measuring points within each section does not exceed 1.5 times the diameter of screw 2. The collection interval of barrel 1 wall temperature distribution data is consistent with the Mooney viscosity data collection interval to ensure point-to-point correspondence between the two sets of data in the time series. After acquiring Mooney viscosity and wall temperature distribution data, time stamps associated with screw position numbers are added. The accuracy of the time stamps is based on the Mooney viscosity data acquisition interval. Correlation verification can only be performed after the time stamps of the two sets of data are aligned. A time stamp deviation exceeding one acquisition interval will cause timing misalignment between the viscosity and temperature signals, affecting the accuracy of lag time measurement. Any data set with an acquisition interruption will be marked with a missing value at the corresponding position; missing values ​​at these times will not be included in the lag time measurement. If wall temperature distribution data shows consecutive missing values ​​for more than three acquisition intervals in the same segment, the entire segment will be marked as invalid and will not be included in the segmented statistics to avoid correlation bias caused by incomplete data.

[0018] In some embodiments, the step of performing correlation verification between the Mooney viscosity data and the wall temperature distribution data to generate a viscosity-temperature consistency index includes: determining the viscosity change lag time and temperature change time of adjacent segments based on the Mooney viscosity data and the wall temperature distribution data to form an inter-segment response lag difference; statistically analyzing the lag difference gradient of each segment according to the screw segment to form an inter-segment lag difference gradient; identifying lag difference exceeding the baseline segment based on the inter-segment lag difference gradient to form an inter-segment process mismatch segment; and assessing the correlation degree between the inter-segment process mismatch segment and the wall temperature distribution data to form a viscosity-temperature consistency index.

[0019] Based on Mooney viscosity data and wall temperature distribution data, the lag time of viscosity change and temperature change between adjacent sections are determined to form the inter-segment response lag difference. In the wall temperature distribution data, the onset time t_T of temperature change at each screw segment measuring point is defined as the moment when the absolute change in temperature at that measuring point first exceeds the threshold ΔT (unit: °C) within one acquisition interval. The onset time t_ML of viscosity response at the corresponding segment position in the Mooney viscosity data is defined as the moment when the change in viscosity value first exceeds the threshold ΔML (unit: MU). The viscosity response lag time τ at the same screw segment position is τ = t_ML - t_T, where τ is in seconds. A positive τ indicates that the viscosity response lags behind the temperature change, while a negative τ indicates that the viscosity response precedes the temperature change. The larger the absolute value of τ, the more significant the viscosity-temperature time-series coupling deviation of that segment. The temperature change time Δt_T is defined as the duration from t_T to the temperature stabilization point in the wall temperature distribution data. Stabilization is determined by the temperature change being less than 10% of ΔT within three consecutive acquisition intervals. Δt_T is measured in seconds. The shorter the Δt_T, the faster the wall temperature adjustment response in that segment. The τ and Δt_T values ​​of all adjacent segment pairs are arranged sequentially from the screw axial feeding section to the homogenization section, forming the inter-segment response hysteresis difference. The larger the τ / Δt_T ratio in the inter-segment response hysteresis difference, the slower the Mooney viscosity data of that segment tracks the changes in wall temperature distribution data. The τ values ​​of each segment pair in the feeding section are usually higher than those in the homogenization section because the rubber compound in the feeding section is in the transition stage from solid to melt, and the viscosity response to temperature changes is affected by the phase transition process, resulting in an inherent hysteresis. In the homogenization section, the rubber compound is fully plasticized, and a large τ value indicates a mismatch between the wall temperature setting and the flow state of the rubber compound in that section. The monotonically decreasing τ value along the axial direction in the inter-segment response hysteresis difference indicates that the plasticization of the rubber compound gradually stabilizes as extrusion progresses. When the τ value locally rebounds in the middle section, it suggests that the viscosity-temperature response coupling deviation at that point expands again, forming a significant contrast with the gradual transition characteristics of adjacent segments.

[0020] The inter-segment hysteresis gradient is formed by statistically analyzing the hysteresis gradient of each screw segment. The difference τ value between adjacent screw segments is calculated pairwise, and the difference Δτ is divided by the axial center distance L (unit: mm) between the two segments to obtain the hysteresis gradient G at that location. G = Δτ / L, where Δτ is in seconds and G is in seconds / mm. A larger G indicates a higher spatial rate of change in the viscosity response hysteresis between adjacent segments. G is calculated pairwise along the axial direction for each segment's τ value. A positive G indicates increasing hysteresis along the extrusion direction, and a negative G indicates decreasing hysteresis. A sudden increase in the absolute value of G corresponds to a spatial abrupt change in the viscosity-temperature response coordination between adjacent segments. When this sudden increase coincides with a screw groove depth change node, it indicates that a sudden change in cross-sectional area alters the heated area and shear heat distribution of the rubber compound, representing a geometric cause of viscosity-temperature mismatch. The G values ​​of all adjacent segment pairs are sequentially connected along the screw axis to form the inter-segment hysteresis gradient. The finer the segment division, the higher the accuracy of the gradient in locating local abrupt changes. For example, if the G value of an adjacent segment pair is significantly higher than that of the pairs before and after it, the inter-segment hysteresis gradient at that position shows an isolated peak, indicating that there is a local decoupling between the heating and viscosity response of the rubber at that section, which is significantly different from the continuous transition characteristics of the segments on both sides. Segment pairs marked as invalid in the inter-segment response hysteresis are also marked as invalid at the corresponding positions in the inter-segment hysteresis gradient and are not included in the baseline calculation. This ensures that the statistical representativeness of the inter-segment hysteresis gradient is not affected by missing value segments. Invalid positions are interpolated in the inter-segment hysteresis gradient by the average of the valid G values ​​on both sides to maintain the continuity of the axial arrangement and are not included in the baseline determination.

[0021] Inter-segment process mismatch sections are formed by identifying hysteresis gradients that exceed the baseline. The baseline value is determined by the median of all valid G values ​​in the inter-segment hysteresis gradient. Taking the median eliminates the influence of extreme abrupt changes on the baseline level. Areas where the absolute value of G continuously exceeds 1.5 times the baseline value and covers three or more consecutive screw segments are identified as exceeding the baseline. The requirement of continuous coverage distinguishes isolated noise points from actual process mismatch sections. The starting and ending segments of the exceeding baseline section are marked according to their axial positions. The peak G value segment within the section is the screw section with the most significant viscosity-temperature response mismatch. When the peak segment coincides with the end of the feeding section, it indicates that the temperature rise in the feeding zone lags behind the change in rubber viscosity. When the peak segment is located in the middle of the compression section, it is usually related to a sudden increase in shear heat caused by changes in screw channel depth. These two types of positional characteristics are distinguished by directly mapping the peak segment number to the physical structure of the barrel. If two adjacent baseline-exceeding segments in the inter-segment hysteresis gradient are less than two screw segments apart, they are merged into one inter-segment process mismatch segment. This merging process ensures that neighboring baseline-exceeding segments caused by the same physical cause remain complete and continuous segments. All baseline-exceeding segments are aggregated one by one from the feeding segment to the homogenization segment to obtain the inter-segment process mismatch segments. Among them, segments covering a larger number of screw segments correspond to a wider range of viscosity-temperature mismatch, while segments covering fewer segments correspond to occasional mismatch in local cross-sections. The causes and impact ranges of the two types of segment mismatches are different, and both are included in the inter-segment process mismatch segment to fully describe the abnormal distribution of viscosity-temperature response of the current batch of rubber throughout the screw. The magnitude of the absolute value of the peak value G in each segment of the inter-segment process mismatch segment reflects the severity of the mismatch. When the peak value G of multiple segments is significantly higher, it indicates an overall deviation in the viscosity-temperature coordination of the current batch of rubber. When the peak value G of a single segment is prominent while the peak value G of other segments is stable, it suggests an independent anomaly in a local heating unit or structure.

[0022] A viscosity-temperature consistency index is formed by assessing the correlation between inter-segment process mismatch zones and wall temperature distribution data. For each screw segment covered by the inter-segment process mismatch zone, the difference ΔTw (unit: °C) between the measured wall temperature and the target process temperature is extracted from the wall temperature distribution data. A positive ΔTw indicates that the measured wall temperature is higher than the set value, while a negative ΔTw indicates that the measured wall temperature is lower than the set value. The larger the absolute value of ΔTw, the greater the deviation in wall temperature at that location. For each segment within the process mismatch zone, the absolute value of G and the corresponding |ΔTw| are paired to calculate the Pearson correlation coefficient r. The closer r is to 1, the higher the positive correlation between the viscosity-temperature mismatch degree and the wall temperature deviation in that segment, indicating that the wall temperature deviation is the main cause of the viscosity-temperature mismatch in that segment. The lower r is, the more likely the viscosity-temperature mismatch is due to fluctuations in the rubber compound formulation or uneven distribution of shear heat, and the wall temperature adjustment has a limited effect on improving the segment. For example, if the r value of a homogenization segment is consistently below 0.3 while the absolute value of G is still high, it suggests that the fundamental cause of the viscosity-temperature mismatch in that segment is the batch-to-batch difference in the viscosity of the rubber compound, and simply adjusting the wall temperature has a limited effect on improving the consistency of that segment. The viscosity-temperature consistency index is based on the weighted average of the r values ​​of all segments in the inter-segment process mismatch zone. The weight is determined by the proportion of the number of screw segments covered by each segment to the total number of segments covered by the inter-segment process mismatch zone. The wider the coverage of the mismatch zone, the greater its contribution to the viscosity-temperature consistency index. When the overall r value is low, the viscosity-temperature consistency index score is low, indicating poor consistency between the current batch wall temperature distribution data and Mooney viscosity data. It is necessary to check the cause of the mismatch in conjunction with the rubber compound formulation and process parameters.

[0023] Step S12: Evaluate the temperature difference distribution of the wall temperature distribution data to generate a segmented plasticizing progress distribution. Measure the axial temperature difference between the feeding section, compression section, and homogenization section from the wall temperature distribution data to generate an inter-segment temperature gradient. Based on the segmented plasticizing progress distribution and the inter-segment temperature gradient, determine the insufficiently plasticized sections and construct a segmented plasticizing process scheme.

[0024] Specifically, a temperature difference distribution assessment was conducted on the wall temperature distribution data to generate a segmented plasticizing progress distribution. The measured wall temperature at thermocouple measuring points within each screw functional section was compared point-by-point with the target process temperature for that section. The axial distribution pattern of the difference reflects the uniformity of the wall temperature along the screw direction. Measuring point intervals with consistently high absolute differences indicate an imbalance between heating output and the heat absorption demand of the rubber compound. A distribution pattern where the absolute difference first increases and then decreases along the axial direction corresponds to a localized overheating zone within that section. The mean of the differences at all measuring points in each functional section was statistically analyzed separately for the feeding section, compression section, and homogenization section. A smaller mean difference indicates that the overall wall temperature of that section is close to the target process temperature; a larger mean difference indicates a greater gap between the heat received by the rubber compound in that section and the heat required for normal plasticizing. The segmented plasticizing progress was scored using the ratio of 1 minus the mean difference to the target temperature difference. A score closer to 1 indicates a higher degree of matching between the wall temperature distribution and the plasticizing heat demand for that section. In a certain feeding section, the initial temperature of the rubber compound was low, causing the average difference value to remain high for an extended period. This resulted in the plasticizing progress score for this section consistently being lower than that of the compression and homogenization sections. The difference in progress scores between this section and adjacent functional sections is clearly reflected in the segmented plasticizing progress distribution. Conversely, if the average difference value in the homogenization section is close to zero, it indicates that the rubber compound has fully reached the target heat level in this section, and the plasticizing progress score approaches full value. The average difference values ​​and corresponding plasticizing progress scores for each functional section in the wall temperature distribution data are arranged sequentially from the feeding section to the homogenization section, forming the segmented plasticizing progress distribution. The segmented plasticizing progress distribution shows a clear contrast between functional sections exhibiting sudden drops in progress scores and the continuous transition patterns of adjacent sections. The larger the drop, the more severe the heat deficit in that section. When the progress scores of multiple functional sections show a step-like continuous decline, it indicates a systematic deviation between the overall screw heating settings and the heat requirements of the current batch of rubber compound.

[0025] The axial temperature difference between the feeding section, compression section, and homogenization section is determined from the wall temperature distribution data to generate the inter-section temperature gradient. At the junction of two adjacent functional sections, the wall temperature is measured at a point near the junction. The temperature difference ΔTs (unit: °C) between the two points is the inter-section axial temperature difference at that junction. A positive ΔTs value indicates a temperature increase along the extrusion direction. During normal plasticizing, ΔTs at the junction of the feeding section and compression section should be positive and its magnitude should correspond to the compression ratio. At the junction of the compression section and homogenization section, ΔTs should approach zero, indicating that the plasticizing of the rubber compound has stabilized. The axial temperature gradient Gs within each functional section is obtained by the ratio of the temperature difference ΔTs_internal (unit: °C) at the beginning and end of the section to the section length Ls (unit: mm), where Gs = ΔTs_internal / Ls. The larger Gs is, the more drastic the axial temperature change of the section's wall, and the greater the degree of uneven heating of the rubber compound within that section. When the extrusion rate increases in a certain compression section but the heating power is not adjusted synchronously, a large temperature difference forms between the first and last measuring points. The temperature gradient (Gs) in this section rises significantly, contrasting sharply with the gradual increase in Gs in the feeding and homogenization sections. The wall temperature distribution data in this section shows a clear axial heat gradient, indicating severe uneven heating of the rubber compound along the axial direction in the compression zone. Conversely, when the homogenization section is relatively stable and the temperature difference between the first and last points is small, Gs approaches zero, indicating a uniform axial wall temperature distribution in this section, and the heat received by the rubber compound remains consistent along the extrusion direction. The inter-segment temperature gradient is obtained by connecting the Gs values ​​of the feeding, compression, and homogenization sections with the ΔTs at each interface along the extrusion direction. In this gradient, the functional section with a sudden increase in Gs forms a distinct difference in temperature gradient compared to the adjacent smooth intervals. The more measuring points in each section in the wall temperature distribution data, the more refined the inter-segment temperature gradient characterizes the axial temperature difference distribution of that section. The calculation accuracy of Gs increases with the increase in measuring point density.

[0026] In some embodiments, the step of determining insufficiently plasticized sections and constructing a segmented plasticizing process scheme based on the segmented plasticizing progress distribution and the inter-segment temperature gradient includes: recording the flow state parameters of the rubber material in each segment of the segmented plasticizing progress distribution to form plasticizing flow characteristics; comparing and verifying the plasticizing flow characteristics with the inter-segment temperature gradient to identify the screw rubber material slippage zone; verifying the continuity of rubber material flow in the screw rubber material slippage zone to identify insufficiently plasticized sections; and constructing a segmented plasticizing process scheme based on the distribution characteristics of the insufficiently plasticized sections.

[0027] The flow parameters of the rubber compound in each segment of the segmented plasticizing progress distribution are recorded to form plasticizing flow characteristics. The plasticizing progress score of each functional segment in the segmented plasticizing progress distribution is combined with the corresponding measured wall temperature. The measured wall temperature values ​​of each segment are weighted using the plasticizing progress score as the weight. The weighted temperature represents the equivalent heating level of the rubber compound in that segment at the current plasticizing degree. A higher equivalent heating level indicates that the rubber compound in that segment is sufficiently heated overall, while a lower equivalent heating level indicates that the plasticizing heat supply of the rubber compound in that segment is weak under the current wall temperature conditions. The flow parameters of the rubber compound in each segment are calculated from the equivalent heating level. When the equivalent heating level is higher than the target process temperature, the corresponding rubber compound is in a low viscosity state, resulting in high screw propulsion efficiency and stable adhesion between the rubber compound and the groove wall. When the equivalent heating level is lower than the target process temperature, the rubber compound viscosity is higher, the friction between the rubber compound and the screw groove wall increases, and the risk of slippage during propulsion increases accordingly. In a certain compression section, the equivalent heating level of the rubber compound with a high viscosity formulation is significantly lower than that of the normal batch. The flow parameters in this section reflect that the rubber compound is in a high viscosity range, and the unevenness of the screw groove friction distribution is much higher than that of the low viscosity batch. The risk of slippage is significantly marked as a high viscosity flow state in the corresponding segment of the plasticizing flow characteristics. If the equivalent heating level in the homogenization section is stable and close to the target temperature, the plasticizing flow characteristics in this section show a low viscosity stable flow state, and the difference in flow parameters between this section and the compression section is clearly reflected in the characteristic distribution. In the segmented plasticizing progress distribution, the continuous functional segments with consistently low progress scores correspond to a continuous low value range of equivalent heating level in the plasticizing flow characteristics. The rubber compound in this range is generally in a high viscosity flow state, and the difference in flow state from the adjacent high equivalent heating level segment is clearly distinguishable in the plasticizing flow characteristics. The equivalent heating level and corresponding high / low viscosity flow state of each functional segment are summarized by segment to form the plasticizing flow characteristics.

[0028] By comparing the plasticizing flow characteristics with the inter-segment temperature gradient, the slippage zone of the screw material was identified. The equivalent heating level of each functional segment in the plasticizing flow characteristics was compared with the corresponding Gs value in the inter-segment temperature gradient. A functional segment whose equivalent heating level was lower than the average value of the entire plasticizing flow characteristics and whose Gs value exceeded the average value of the entire inter-segment temperature gradient by a certain multiple met both conditions. This indicates that the uneven axial distribution of the wall temperature in this segment, coupled with insufficient heating of the rubber material, caused an imbalance in the frictional force distribution of the rubber material in the screw channel of this segment, resulting in relative slippage between the rubber material and the screw wall at local locations. In a certain feeding section, the equivalent heating level was significantly low when the rubber compound temperature was unstable at the beginning of the batch change. Due to the lag in heating power adjustment, the Gs in this section was also high. The combination of these two indicators caused this section to be the first to enter the slippage candidate state. After the operation of subsequent batches stabilized, the equivalent heating level gradually recovered and Gs fell. After both indicators returned to normal levels, this section was removed from the slippage candidate state. In the compression section, if the heating power in the screw channel contraction zone does not increase synchronously with the compression ratio, the high equivalent heating level and high Gs in this section will continue for a long time, and the slippage candidate judgment remains effective throughout the entire compression zone. Adjacent slippage candidate segments are merged into a single screw rubber slippage zone. Individually occurring candidate segments are retained separately. The screw rubber slippage zone is composed of all slippage candidate segments in axial order. The axial start and end positions of each slippage zone, along with the corresponding equivalent heating level and peak value of Gs, are recorded in the screw rubber slippage zone. Slippage zones with lower equivalent heating levels and higher Gs have a more severe slippage risk. Zones with both indicators close to the judgment threshold have a relatively lower slippage risk. Slippage zones in the screw rubber slippage zone are distinguished by mild and severe slippage.

[0029] For example, the step of verifying the continuity of rubber flow and confirming insufficient plasticization in the screw rubber slippage section includes: forming a pressure recovery record based on the pre-pressure recovery situation of each section of the screw rubber slippage section; statistically analyzing the pressure recovery rate of each section of the pressure recovery record to form a recovery rate distribution; determining sections with abnormally high recovery rates based on the recovery rate distribution to form plasticization short supply sections; and screening and confirming insufficient plasticization sections based on the plasticization short supply sections.

[0030] Pressure recovery records are generated based on the pressure recovery of each section in the screw rubber slippage zone. Data from the pressure sensor array 11 at adjacent upstream positions in each section of the screw rubber slippage zone are read point by point during the slippage period. The average pressure within several acquisition intervals before slippage occurs in each section is used as the baseline level of the upstream pressure for that section. The difference between the upstream pressure and the baseline level at each acquisition moment during the slippage period is the pressure recovery amount at that moment. A positive pressure recovery amount indicates that slippage has caused upstream rubber accumulation, and the recovery amount continues to increase as the degree of slippage deepens. When the extrusion volume increases rapidly in a certain compression section, upstream pressure buildup occurs quickly, and the pre-pressure rises sharply within several sampling intervals. The pressure recovery time-series curve shows a steep upward trend followed by a plateau. If slow and gradual slippage occurs in the feeding section, the recovery amount increases linearly and slowly over time. The time-series curve shows a continuous upward trend without a clear inflection point. The upward slope is determined by the viscosity of the rubber compound in that section and the friction coefficient of the screw channel inner wall. The higher the friction coefficient, the steeper the upward slope. The two types of curves are clearly distinguishable in the pressure recovery record, reflecting the differences in the rhythm of slippage and the accumulation mode of pressure in different sections. The pressure recovery time-series curves of each section in the screw rubber slippage zone are summarized into a pressure recovery record by section number. In the pressure recovery record, the section with continuously increasing recovery indicates that the slippage is getting worse over time, while the section with stable recovery indicates that the slippage is stabilizing. The peak value of each section reflects the maximum intensity of upstream pressure accumulation caused by slippage. The higher the peak value, the more severe the axial advance of the rubber in that section is obstructed. The relative height of the peak values ​​of each section in the pressure recovery record reveals the spatial distribution pattern of the severity of screw slippage throughout the entire process.

[0031] The pressure recovery rate of each segment in the pressure recovery record is statistically analyzed to form a recovery rate distribution. The recovery rate v_p is calculated segment by segment from the time-series curve of the pressure recovery amount in each segment of the pressure recovery record, where v_p = ΔPr / Δt, ΔPr is the difference in pressure recovery amount between two adjacent acquisition times (unit: MPa), Δt is the acquisition interval (unit: s), and v_p is in MPa / s. The larger the v_p, the faster the upstream pressure advances at that moment, and the higher the rate of rubber accumulation caused by slippage. In the pressure recovery record, the average value of the v_p sequence for each segment during the continuous slippage period is taken as the representative recovery rate of that segment. The higher the representative recovery rate of a segment, the more severe the disturbance of the upstream pressure distribution caused by the slippage behavior. The dispersion of v_p values ​​at each acquisition time also carries information. Segments with large v_p fluctuations indicate that the slippage is intermittent rather than continuous and stable, with alternating periods of pressure accumulation and brief advances. The upstream pressure oscillates periodically rather than rises monotonically at this point. The representative recovery rate of such intermittent slippage segments is often lower than that of continuous slippage segments, but the impact on the screw mechanical load is more significant. In the homogenization section, when the batch running is of medium viscosity, the recovery rate is relatively low. The v_p time series curve fluctuates slightly within a small amplitude, the accumulation rhythm is stable, the upstream pressure distribution is only slightly affected by slippage, and the standard deviation of the v_p sequence is significantly lower than that of the compression section. In the compression section, when the heating power adjustment is significantly lagging, the recovery rate increases significantly. The v_p curve remains high for a short period of time, the accumulation progresses rapidly, and the recovery rate distribution shows an isolated peak in this section. The v_p curve waveform in this section is a wide-amplitude, high-plateau shape, which is completely different from the narrow-amplitude, low-fluctuation curve shape of the homogenization section. The v_p time series of each section and the corresponding representative recovery rate are aggregated according to the section number to form the recovery rate distribution. In the recovery rate distribution, the v_p waveform and the representative recovery rate together characterize the slippage rhythm of each section.

[0032] Based on the recovery rate distribution, abnormally high recovery rate segments are identified as plasticizing short-supply segments. The mean and standard deviation of the recovery rate representing all segments in the recovery rate distribution are used as the anomaly judgment benchmark. Segments representing recovery rates exceeding the mean plus a certain multiple of the standard deviation are judged as abnormally high recovery rate segments. This threshold strikes a balance between detecting truly abnormal segments and filtering normal rate fluctuations. The physical meaning of the abnormally high segment is that the slippage has caused the upstream rubber compound accumulation rate to be significantly higher than the overall level. The supply of rubber compound downstream in this segment continues to accumulate as the accumulation continues, and the deficit accumulates with the duration of slippage. The rubber compound filling rate in the adjacent downstream segment decreases accordingly. During the period when the filling rate is continuously low, the effective conveying cross section of the screw channel decreases, and the uniformity of extrusion pressure decreases accordingly. During batch transition, a formula change at the final feeding stage led to a temporary increase in viscosity. The frictional propulsion conditions of the rubber compound in this section's screw channel significantly deteriorated, indicating that the rebound rate exceeded the threshold first. Upstream pressure amplified rapidly in this section. In contrast, the compression stage, due to sufficient heat compensation, still had a rebound rate that, while rising synchronously, remained within the threshold. The two stages exhibited a contrasting trend in their rebound rate distributions: one exceeding the threshold and the other being critical. The pressure effect in the exceeding-threshold stage was far stronger than in the critical stage. The evolution of the rebound rate distribution patterns in both stages during this batch transition period clearly demonstrated the process of slippage and loss of control propagating downstream from the final feeding stage. The plasticizing short-supply section is formed by the axial start and end positions of the abnormally high rebound rate sections and the representative rebound rate peak value in axial order. When adjacent sections simultaneously exceed the standard, they are merged into a continuous short-supply section. After merging, the representative rebound rate is taken as the maximum value among the peak values ​​of each section before merging, serving as a representative indicator of overall severity. This ensures that the continuous exceeding range is reflected in the plasticizing short-supply section within a complete axial range.

[0033] Based on the screening of plasticized short-supply sections, insufficient plasticization sections were identified. The degree of rubber shortage in each section of the plasticized short-supply section was quantified by the deviation multiple of the peak recovery rate from the average recovery rate distribution across the entire section. Sections with a high deviation multiple were identified as severely short-supply, while those with a moderate deviation multiple were identified as moderately short-supply. Both severely and moderately short-supply sections were included in the insufficient plasticization section to cover all substantive short-supply sections with varying degrees of rubber shortage. A batch of high-viscosity rubber compound experienced a severe short supply at the end of the feeding stage. The rubber supply deficit accumulated rapidly over several consecutive sampling cycles, with the accumulated amount exceeding a certain proportion of the normal volume of the screw channel at the end of the feeding stage during peak periods. The axial advance of the rubber compound at this point was almost interrupted. Simultaneously, the compression stage, affected by the accumulation, entered a moderate short supply state. The two stages showed a significant difference in deviation ratio, with the deviation ratio of the severe short supply stage far exceeding that of the moderate short supply stage. The combined insufficient plasticization stage covered the entire range from the end of the feeding stage to the compression stage, and the continuous deficit range was fully reflected in the insufficient plasticization stage. If an independent moderate short supply occurred in the homogenization stage, the cause would be different from that of the slippage at the end of the feeding stage. The two were independent in terms of deviation ratio and axial position. The short supply section in the homogenization stage was retained separately in the insufficient plasticization stage, and the adjustment range was determined separately based on its deviation ratio. This was decoupled from the adjustment parameters of the severe short supply at the end of the feeding stage, ensuring that the process adjustment intensity matched the severity of the plasticization deficit in each stage.

[0034] A segmented plasticizing process scheme is constructed based on the distribution characteristics of insufficiently plasticized sections. The distribution characteristics of insufficiently plasticized sections along the screw axis are categorized into two types based on the axial position and pressure gradient difference of each section: concentrated distribution and dispersed distribution. Concentrated distribution refers to insufficiently plasticized sections continuously covering two or more functional sections, while dispersed distribution refers to normal plasticizing sections existing between insufficiently plasticized sections. Concentrated distribution of insufficiently plasticized sections indicates a complete mismatch between the heating power and screw feed rate of the entire section. If concentrated distribution of insufficiently plasticized sections appears simultaneously in both the compression and homogenization sections when a batch of high Mooney viscosity rubber is processed, it indicates that the heat supply in the middle and later sections of the entire screw is lower than the level required for rubber plasticization. The segmented plasticizing process scheme adopts a combined adjustment strategy of overall temperature increase and screw speed reduction for this section. The temperature increase is determined based on the difference between the peak value of the recovery rate represented by each insufficiently plasticized section and the mean value of the recovery rate distribution. The speed reduction is calculated based on the ratio of the axial length of each insufficiently plasticized section to the effective total length of the screw. The dispersed, insufficiently plasticized sections are adjusted independently. If an isolated insufficiently plasticized section appears in a feeding section while the compression and homogenization sections are normal, the segmented plasticizing process scheme only sets wall temperature and rotation speed adjustment parameters for that isolated section, without disturbing the other normally functioning sections, ensuring that the adjustment is precisely directed to the mismatched section. The segmented plasticizing process scheme is obtained by organizing the adjustment parameters of each insufficiently plasticized section and the corresponding axial position number in sequence according to the screw's propulsion direction. The coverage range of the adjustment parameters in the scheme strictly corresponds to the distribution range of the insufficiently plasticized sections.

[0035] Step S13: Based on the viscosity-temperature consistency index and the segmented plasticizing process scheme, conduct segmented viscosity deviation assessment to generate viscosity deviation distribution, redistribute cross-segment heat margin to generate heat compensation scheme, and implement heat-oriented compensation to establish segmented control threshold based on the heat compensation scheme.

[0036] Specifically, a segmented viscosity deviation assessment is conducted based on the viscosity-temperature consistency index and the segmented plasticizing process to generate a viscosity deviation distribution. The measured Mooney viscosity data of each screw functional segment is compared segment by segment with the target viscosity range corresponding to that segment in the segmented plasticizing process. Segment deviations where the measured value falls within the target range are zero. Segment deviations where the measured value is higher than the upper limit or lower than the lower limit of the target range are represented by the difference between the measured value and the nearest boundary. A positive deviation indicates high viscosity and high flow resistance, while a negative deviation indicates low viscosity and excessively thin flow of the material in that segment. The viscosity-temperature consistency index incorporates segmented deviation assessment as a weighting correction. When the overall consistency index is low, the viscosity-temperature correlation deviation across the entire segment is large, and the response of the measured Mooney viscosity data of each segment to the current wall temperature exhibits a systematic lag, reducing the overall reliability of the deviation. The viscosity-temperature consistency index corrects the deviation of each segment in a multiplicative manner; the lower the overall index, the more conservative the corrected deviation of each segment, avoiding the amplification of viscosity-temperature timing errors into false viscosity anomalies. In the segmented plasticizing process plan, the insufficient plasticizing sections marked are simultaneously verified in the segmented deviation evaluation. When insufficient plasticizing and high viscosity deviation occur simultaneously in a certain feeding end section, the two anomalies are superimposed in that section. The corrected deviation is higher than that of a functional section with only a single anomaly, indicating that this section is constrained by both insufficient heat and high viscosity, and the process adjustment difficulty is significantly higher than that of a single-factor imbalance section. The corrected deviations of each functional section are arranged in axial order to form a viscosity deviation distribution. The trend of the deviation along the axial direction in the viscosity deviation distribution reflects the viscosity uniformity of the rubber compound throughout the screw feed. When the overall deviation is high, it indicates that the viscosity of the current batch of rubber compound deviates systematically from the target range set in the process plan. When the deviation is prominent in a local section, it indicates that there is an independent cause of viscosity-temperature imbalance in that section.

[0037] In some embodiments, the step of redistributing the cross-segment heat margin to generate a heat compensation scheme based on the viscosity deviation distribution includes: checking the deviation level of each segment of the viscosity deviation distribution to form an inter-segment deviation distribution; extracting the heat margin of each segment from the inter-segment deviation distribution to form a heat margin distribution; assessing the cross-segment heat compensation requirement based on the heat margin distribution to form a cross-segment heat compensation requirement comparison; and redistributing the cross-segment shear heat based on the cross-segment heat compensation requirement comparison to generate a heat compensation scheme.

[0038] The viscosity deviation distribution is checked to identify the deviation levels of each segment, forming an inter-segment deviation distribution. The corrected deviation for each functional segment in the viscosity deviation distribution is calculated using the feeding segment, compression segment, and homogenization segment as units, with each segment having its own mean value. A higher mean value indicates a greater deviation of the overall viscosity of the rubber compound from the target range. Functional segments with positive mean values ​​have generally high viscosity and require additional heating to bring the viscosity back to the target range, while functional segments with negative mean values ​​have generally low viscosity and the current wall temperature exceeds the level required for normal plasticization in that segment. The mean deviation values ​​of each functional segment are arranged axially to form the inter-segment deviation distribution. The greater the difference in mean deviation values ​​between adjacent functional segments, the steeper the viscosity gradient between the two segments, and the more dramatic the viscosity jump when the rubber compound flows across segments. This jump significantly affects the uniformity of the shear force distribution on the screw channel wall. When the average deviation of a certain compression section is significantly higher than that of the feeding and homogenization sections, the inter-section deviation distribution exhibits a peak shape with a prominent mid-section. This indicates that the relatively insufficient heat received by the rubber compound in the compression zone is the main source of the overall high viscosity. The average deviations of the feeding and homogenization sections on both sides of the peak are relatively stable, indicating that the imbalance is concentrated in the compression zone rather than a systematic deviation across the entire section. When the average deviation of the homogenization section is consistently negative, a trough appears in the inter-section deviation distribution at the end, indicating that the wall temperature setting in the homogenization zone is too high, and the rubber compound has been excessively softened before entering the die head. The depth of the trough is positively correlated with the extent to which the wall temperature of the homogenization section exceeds the reasonable range; the deeper the trough, the stronger the need for adjustment. When the average deviation in the inter-section deviation distribution is generally high, it indicates a systematic positive deviation between the viscosity of the current batch of rubber compound and the process target range. Conversely, when it is generally low, the opposite is true. These two types of systematic deviations are manifested in the inter-section deviation distribution as an overall increase or decrease in the average level across the entire section, which is distinctly different in distribution shape from the single peak or trough shape with a prominent local section.

[0039] The heat reserve of each segment is extracted from the inter-segment deviation distribution to form a heat reserve distribution. The heat reserve of each functional segment is obtained by multiplying the difference between the current wall temperature and the target temperature of that segment by the specific heat capacity and mass flow rate of the rubber compound, in units of kW. A positive heat reserve value indicates that the current heating output of that segment is higher than the level required for plasticization of the rubber compound, and there is excess heat that can be transferred to segments with higher deviations. A negative heat reserve value indicates that the heating output of that segment is lower than the level required for plasticization, and there is a heat deficit. In the inter-segment deviation distribution, functional segments with a negative mean deviation usually correspond to segments with positive heat reserves. The correspondence between the two in terms of numerical signs stems from the same physical essence: the rubber compound in that segment is overheated, resulting in a viscosity lower than the target range, and the excess heat is quantified in the form of heat reserve. When the average deviation of a homogenization section is consistently negative and the wall temperature is significantly higher than the target process temperature, the heat reserve in this section exhibits a large positive value in the heat reserve distribution, which can be transferred to sections with higher average deviations, such as the compression section. When the average deviation of a feeding section is positive and the wall temperature is close to the target lower limit, the heat reserve in this section is negative, requiring external heating to compensate for the viscosity deviation, and corresponds to a negative value range in the heat reserve distribution. The heat reserve of each functional section is aggregated segment by segment along the screw axis to form the heat reserve distribution. The axial positional relationship between the positive and negative value segments determines the transfer direction of cross-segment heating. When the positive value segment is upstream of the negative value segment, heat is naturally conducted along the extrusion direction, giving it a geographical advantage. When the positive value segment is downstream of the negative value segment, cross-segment heating needs to be indirectly achieved through the combined adjustment of screw speed and heating power. The larger the absolute value of the heat reserve in each segment of the heat reserve distribution, the more significant the heat surplus or deficit of the corresponding segment.

[0040] Based on the distribution of residual heat, the cross-segment heating demand is assessed to form a cross-segment heating demand comparison. Functional segments with a positive mean deviation and negative residual heat in the residual heat distribution constitute heating demand segments. The heating demand is determined by the absolute value of the residual heat in this segment, and priority is assigned according to the magnitude of the corresponding mean deviation. The higher the mean deviation and the larger the residual heat gap, the greater the heating demand segment requires. When both indicators are high, it indicates that the viscosity of the rubber in this segment deviates significantly from the target range and its own heat reserve is severely insufficient, making it difficult to correct by heating adjustment of this segment alone. Functional segments with positive residual heat in the residual heat distribution constitute candidate heat supply segments. The maximum heat output of a candidate supply segment is constrained by its positive residual heat value and the residual heat between the current wall temperature and the upper limit of the equipment heating. Candidate segments with sufficient residual heat but whose wall temperature is close to the upper limit of the heating are constrained by the equipment and their actual output heat is lower than the nominal value of the residual heat. The smaller value between the two constraints is taken as the upper limit of the actual available heat for the candidate segment. The heat replenishment demand segment and the supply candidate segment are paired according to the absolute value of the heat margin, from largest to smallest. The heat replenishment demand segment with the largest absolute value is preferentially paired with the supply candidate segment with the most abundant heat margin. When the heat replenishment demand of a certain compression segment is large, the heat margin of a single supply candidate segment is insufficient to cover it. In this case, the two supply candidate segments jointly allocate the heat, each undertaking a certain proportion of the total heat replenishment. The allocation ratio is determined based on the ratio of the actual available heat upper limits of the two candidate segments. The candidate segment with more abundant heat margin undertakes a larger proportion. The sum of the joint allocation of the two segments covers the entire heat replenishment demand of the compression segment. The pairing relationship between each heat replenishment demand segment and the corresponding supply candidate segment, as well as the heat replenishment allocation value, are integrated into a cross-segment heat replenishment demand comparison using axial position numbers as an index. In this comparison, the heat replenishment allocation value of each pair represents the scale of heat transfer between the pairs of segments. The more pairs there are, the more dispersed the viscosity deviation distribution of the current batch of rubber compound is, and the wider the functional segment range involved in the cross-segment heat scheduling.

[0041] A heat compensation scheme is generated by redistributing cross-segment shear heat based on the comparison of cross-segment heat replenishment demand. The heat transfer of each pair in the cross-segment heat replenishment demand comparison is achieved by adjusting the local speed of the screw in the supply candidate segment. The increase in speed increases the amount of shear heat generated in the screw groove of that segment, and the excess shear heat is conducted axially to the adjacent heat replenishment demand segment to make up for the heat gap of the heat replenishment demand segment. The local speed adjustment range is determined by the ratio of the heat replenishment distribution value of the corresponding pair in the cross-segment heat replenishment demand comparison to the shear heat generation coefficient of that segment. The shear heat generation coefficient (unit: kW / rpm) is calibrated by the product relationship between the viscosity of the rubber compound and the speed. The higher the viscosity of the batch, the greater the amount of shear heat generated under the same speed increment, and the speed adjustment range can be reduced accordingly. When a compression section is a heat-replenishing demand section and an adjacent homogenization section is a supply candidate section, after a slight increase in the rotational speed of the homogenization section, the shear heat increment is conducted to the compression section through the interface between the sections. The wall temperature of the compression section rises slowly with the increase of the transferred heat, and the viscosity deviation gradually narrows as the wall temperature rises. The increase in the rotational speed of the homogenization section needs to be controlled within the range where the plasticized state of the rubber in this section does not experience overheating rebound. The upper limit of this range is constrained by the upper limit of the heat replenishment output of the homogenization section in the cross-section heat replenishment demand comparison. If there is a normal functional section between the heat-replenishing demand section and the supply candidate section, the heat conduction path increases, and the conduction attenuation needs to be deducted from the heat replenishment allocation value. The actual rotational speed adjustment range allocated to the supply candidate section is increased accordingly to compensate for the conduction loss. The heat compensation scheme is obtained by combining the paired shear heat adjustment parameters with the corresponding axial position number of the section along the screw axis. The adjustment parameters of each section in the scheme are independent of each other. The difference in the speed adjustment range of adjacent sections is clearly reflected in the heat compensation scheme. The overall adjustment direction strictly corresponds to the heat transfer path in the comparison with the cross-section heat replenishment demand. The flow direction of heat from the surplus section to the gap section is intuitively presented in the parameter distribution of the heat compensation scheme.

[0042] In some embodiments, the step of establishing segmented control thresholds by implementing thermal directional compensation according to the thermal compensation scheme includes: summarizing the thermal compensation execution status of each segment according to the thermal compensation scheme to form a compensation execution record; screening the secondary viscosity rise segment of the compensation execution record to form an overcompensated segment; performing a unit heat temperature rise decay analysis on the overcompensated segment to confirm the upper limit of the compensation threshold; and deducing the allowable compensation heat for each segment based on the upper limit of the compensation threshold to establish the segmented control threshold.

[0043] Based on the thermal compensation scheme, a compensation execution record is formed by summarizing the thermal compensation execution status of each segment. After the speed adjustment command for each functional segment in the thermal compensation scheme is issued, the wall temperature sensor and Mooney viscosity data acquisition module of each segment continuously record during the compensation execution period. The wall temperature sensor reads the measured wall temperature point by point during the compensation execution period at normal acquisition intervals, and the Mooney viscosity data synchronously records the viscosity change at the corresponding segment position. The difference between the measured wall temperature at each acquisition moment and the reference wall temperature before compensation is taken as the compensation temperature rise at that moment. The viscosity change is referenced to the reference viscosity before compensation. A positive value for viscosity decrease indicates that the compensation is effective, and a positive value for viscosity increase indicates that overcompensation has occurred. In a certain compression segment, the compensation temperature rise continuously increases in the initial stage of compensation, and the viscosity steadily decreases as the wall temperature rises. The compensation execution is normal in this stage. As the compensation time extends, after the wall temperature of this segment exceeds the optimal plasticizing temperature range of the rubber compound, the rubber compound tends to crosslink due to overheating, and the viscosity changes from decreasing to increasing. The viscosity increase appears in the compensation execution record, indicating that the compensation allocation of this segment in the thermal compensation scheme has exceeded the effective range. The time-series curves of the compensated temperature rise and viscosity change during the compensation execution period of each functional segment are compiled into a compensation execution record in sequence by segment number. The correspondence between the two types of time sequences in each segment of the record reflects the thermal compensation efficiency of that segment. The stage in which the temperature rise increases and the viscosity change decreases simultaneously corresponds to normal compensation efficiency. The stage in which the temperature rise increases and the viscosity change stops decreasing or even increases corresponds to a decline in compensation efficiency. The transition time between the two stages corresponds to the inflection point of compensation efficiency in the compensation execution record.

[0044] The compensation execution record is used to screen for overcompensated sections by performing a second viscosity increase segment screening. The viscosity change time-series curve of each functional segment in the compensation execution record is checked segment by segment. The moment when the viscosity change turns from negative to positive is defined as the start time of the second viscosity increase segment. The segment in which the viscosity change remains positive and the absolute value continues to increase for several consecutive sampling intervals after the start time of the second viscosity increase is judged as the viscosity second increase segment. The judgment of continuous increase requires distinguishing between the brief random fluctuation of viscosity near zero value and the true second increase. The sampling time when a single point crosses zero and then immediately falls back does not trigger the determination of the viscosity second increase segment. In a certain homogenization segment, a second viscosity increase occurred during the compensation execution phase. The viscosity change continued to rise after turning positive, and the slope of the time series curve was close to the absolute value of the slope of the viscosity decrease phase before compensation. This indicated that the viscosity rebound rate caused by overheating was comparable to the viscosity decrease rate during the effective compensation phase, and the degree of overcompensation was relatively significant. This segment was the first to enter the second viscosity increase phase during the screening. In a certain compression segment, the viscosity change briefly crossed zero at some sampling moments and then fell back. The time series curve fluctuated slightly near the zero value, and there was no continuous increasing trend after crossing zero. This segment did not trigger the determination of the second viscosity increase phase and maintained the effective compensation state during the screening of compensation execution records. The functional segments containing the second viscosity increase segment are grouped sequentially according to their axial position to form an overcompensated segment. The starting time of the second viscosity increase in each segment within this segment is recorded together with the corresponding compensation temperature rise. The earlier the starting time, the more likely that the segment has already experienced overheating rebound when the compensation amount is small, and the weaker its ability to withstand the compensation heat. The steeper the slope of the second viscosity increase, the more severe the overheating rebound. The slope is directly related to the sensitivity of the rubber compound formulation to overheating. The higher the sensitivity of the formulation batch, the steeper the slope of the second viscosity increase and the earlier the overcompensated segment is determined.

[0045] For example, the step of performing unit heat temperature rise attenuation analysis on the overcompensated section to confirm the upper limit of the compensation threshold includes: measuring the outlet temperature of each section of the rubber compound and the compensated input heat to form a unit heat temperature rise curve based on the overcompensated section; statistically analyzing the continuous decrease rate of temperature rise values ​​at each level in the unit heat temperature rise curve to form an attenuation rate distribution; determining the abrupt change point of the attenuation rate distribution to locate the inflection point of decreasing conduction efficiency; and confirming the second-order viscosity increase boundary based on the inflection point of decreasing conduction efficiency to form the upper limit of the compensation threshold.

[0046] Based on the measurement of the outlet temperature of the rubber compound in each section of the overcompensated section and the compensation input heat, a unit heat temperature rise curve is formed. During the compensation execution period, the outlet temperature sensor of each functional section in the overcompensated section reads the temperature of the rubber compound leaving the section at each moment. The difference between the outlet temperature and the reference outlet temperature before compensation is taken as the outlet temperature rise at that moment. The outlet temperature rise is more representative of the overall heating effect of the compensation heat on the rubber compound than the inlet wall temperature rise. The inlet wall temperature rise only reflects the instantaneous response of the heating element, while the outlet temperature rise integrates the heat conduction and plasticizing heat absorption of the rubber compound throughout the entire screw channel. The difference between the two also reflects the degree of internal heat consumption of the rubber compound in that section. The compensated input heat at any given moment is determined by integrating the sum of the heating power and the shear heat generation power of that section. The temperature rise per unit heat is obtained by dividing the outlet temperature rise by the cumulative compensated input heat at the same moment. The temperature rise per unit heat is higher in the initial stage of compensation, indicating that the rubber compound has a high conversion efficiency of the input heat before reaching the optimal plasticizing temperature. As compensation continues, the temperature rise per unit heat gradually decreases, indicating that the marginal efficiency of heat conversion to higher temperatures decreases as the rubber compound temperature increases. The temperature rise per unit heat of each functional section in the compensation zone is plotted moment by moment along the compensation progression to form a temperature rise per unit heat curve. The moment when the slope of the curve changes from negative to a larger negative value corresponds to the stage where the heat conversion efficiency decreases rapidly. In the early stage of compensation, the curve of a certain compression section shows a relatively flat and gently decreasing shape, and the temperature rise per unit heat remains high, indicating that the rubber compound is still in the high-efficiency heat conversion zone. In the later stage of compensation, the slope of the curve drops sharply to a larger negative value, and the temperature rise drops rapidly, indicating that the rubber compound in this section has crossed the optimal plasticizing temperature range. In a certain homogenization segment, the curve slope was relatively uniform throughout the compensation period, with no obvious sharp drop in inflection point, indicating that the rubber compound in this segment was in a steady-state plasticization stage, and the heat dissipation and absorption rhythm was close to linear. The difference in curve shape between the two segments was clearly contrasted in the unit heat temperature rise curve. The functional segment with a generally flat curve showed a slow decline in heat utilization efficiency, while the functional segment with a steep drop in curve slope showed a rapid deterioration in heat utilization efficiency.

[0047] The decay rate distribution is formed by continuously decreasing the temperature rise values ​​at each stage of the unit heat temperature rise curve. The unit heat temperature rise values ​​at each time point in the unit heat temperature rise curve are subtracted from each other, and the difference is divided by the time interval to obtain the decay rate v_d at that time point. v_d = Δ(δT / ΔQ) / Δt, where δT is the outlet temperature rise (°C), ΔQ is the cumulative compensated input heat (kJ), Δ(δT / ΔQ) is the difference in unit heat temperature rise values ​​between two adjacent time points (°C / kJ), and Δt is the sampling interval (s). The unit of v_d is °C / (kJ·s). The larger the absolute value of v_d, the faster the unit heat temperature rise curve decreases at that time point, and the more severe the decay of heat transfer efficiency. The v_d values ​​at each time point are connected in series along the compensation progression time sequence to form the decay rate distribution. In this distribution, v_d usually maintains a relatively small absolute value level in the early stage of compensation, corresponding to the normal stage of slow linear decay of heat transfer efficiency. During this stage, the v_d time sequence curve is approximately horizontal, and the differences between sampling times are small. In a certain feeding section, the absolute value of v_d shows a phased increase in the later stage of compensation, and the decay rate distribution exhibits local peaks during this period. The width of the local peaks corresponds to the duration of the rubber compound in the phase transition zone. The narrower the peak, the more rapid the phase transition, indicating that the plasticization state of the rubber compound undergoes a phased abrupt change, and the conversion path from heat to temperature rise changes nonlinearly. In the homogenization section, if the absolute value of v_d remains stable throughout, the decay rate distribution in this section shows a nearly horizontal straight line, indicating that the plasticization state of the rubber compound in the homogenization section progresses uniformly throughout the compensation period, which contrasts sharply with the local peak shape in the decay rate distribution of the feeding section. After summarizing the v_d sequences of each functional section, the functional section with the earlier the abrupt change in v_d in the decay rate distribution has a narrower tolerance window for the compensated heat. The order of the abrupt changes in each segment in the decay rate distribution directly reflects the spatial differences in the heat resistance of the rubber compound in each functional section.

[0048] The rate abrupt change point is determined by analyzing the decay rate distribution to pinpoint the inflection point of decreasing conduction efficiency. The mean and standard deviation of the v_d sequence for each functional segment in the decay rate distribution are used as the criteria for abrupt change. A rate abrupt change point is defined as the moment when the absolute value of v_d increases by more than a certain multiple of the standard deviation of the v_d sequence within a single acquisition interval. This abrupt change point corresponds to the turning point in the decay rate distribution where slow decay suddenly transitions to rapid decay. A greater difference in the slope of the v_d curve before and after the turning point indicates a more concentrated phase transition effect corresponding to the plasticizing critical temperature of the rubber compound in that segment. The physical meaning of the rate abrupt change point is that at this moment, the compensated input heat has pushed the rubber compound past the critical temperature of its current plasticizing state. The degrees of freedom of the rubber compound molecular chains suddenly increase, and the proportion of heat dissipated through changes in molecular chain configuration increases sharply, while the proportion converted into measurable temperature rise decreases sharply. The inflection point of decreasing conduction efficiency is thus located at the rate abrupt change point. A sudden rate change point in the compression section occurs in the middle of the compensation execution record. Before the change point, v_d increases slowly and linearly; after the change point, v_d jumps sharply and remains high for several subsequent acquisition intervals. The slope of the decay rate distribution curve on both sides of the change point forms a clear discontinuity. The larger the discontinuity, the more significant the phase change effect of the rubber compound in that section. A high-amplitude discontinuity indicates that the viscosity will rebound rapidly after the compensation amount in that section exceeds the critical value. If the sudden rate change point in the homogenization section occurs early in the compensation execution record, it means that the rubber compound in that section has already exceeded the plasticizing critical temperature when the compensation amount is small. The heat conduction efficiency has already entered the rapid decay zone at a low compensation amount. The wall temperature value corresponding to the inflection point is relatively low, and the margin for the heat compensation is correspondingly smaller. The inflection points of decreasing conduction efficiency in each functional section are summarized in axial order. The compensation temperature rise corresponding to the inflection point indicates the total temperature rise that the rubber compound has obtained when the conduction efficiency of each section begins to drop sharply. The smaller the total temperature rise, the narrower the safety margin for heat compensation in the functional section.

[0049] Based on the inflection point of decreasing thermal conductivity, the boundary of the second viscosity increase is identified, forming the upper limit of the compensation threshold. The inflection point temperature rise corresponding to each functional segment of the thermal conductivity decrease inflection point is compared with the viscosity change at the start of the second viscosity increase in that segment. The closeness of the timing between the inflection point temperature rise and the start of the second viscosity increase verifies the causal relationship between the two. The smaller the time difference, the more synchronized the triggering mechanisms of the sudden drop in thermal conductivity and viscosity rebound are, indicating that the physical mechanism of the rubber compound overheating causing the second viscosity increase is more direct in this segment's causal chain. In a certain compression segment, the two are triggered almost simultaneously, with the sudden drop in thermal conductivity and viscosity rebound driven by the same overheating event, and the time difference is close to zero. In the homogenization segment, if the time difference is large, the viscosity continues to decrease for a period after the inflection point temperature rise before rebounding, indicating that there is a buffer zone in the thermal-viscosity response of the rubber compound in this segment, and there is a certain operational intervention window between the overheating event and the viscosity rebound. The two types of time difference patterns are clearly distinguishable in the time-series comparison of viscosity changes in each segment. The wall temperature value corresponding to the inflection point of decreasing heat conduction efficiency is obtained by adding the inflection point temperature rise to the reference wall temperature of each functional segment. This wall temperature value is the second viscosity rise boundary of that segment. The rise boundary transforms the temporal characteristics of the sudden drop in heat conduction efficiency into an upper temperature limit that can be directly used for wall temperature adjustment. The viscosity second rise boundaries of all overcompensated functional segments are summarized in axial order. The level of the independent boundary value of each segment reflects the difference in the tolerance of different functional segment rubber compounds to overheating. The lowest of all independent boundary values ​​is taken as the cross-segment conservative benchmark. Functional segments whose independent boundary values ​​are higher than the conservative benchmark retain the measured boundary value of this segment. The cross-segment conservative benchmark and the retained independent boundary values ​​of each segment are combined to obtain the upper limit of the compensation threshold. This upper limit, with its coexistence of both, ensures that the high heat resistance segment and the low heat resistance segment each apply the upper limit constraint that conforms to the characteristics of the rubber compound in this segment.

[0050] The segmented control threshold is established by inversely calculating the allowable compensable heat for each segment based on the upper limit of the compensation threshold. The upper limit of the compensation threshold corresponds to the highest allowable wall temperature of each functional segment. The allowable compensable heat (kW) for each segment is obtained by multiplying the upper limit of the compensation threshold and the difference between the reference wall temperature of that segment and the specific heat capacity and mass flow rate of the rubber compound. The larger the allowable compensable heat for a functional segment, the more ample the margin between its wall temperature and the upper limit of the compensation threshold, and the greater the compensation range it can withstand. The smaller the margin, the more constrained the allowable compensable heat for a functional segment, and the narrower the speed adjustment space. The allowable compensable heat for each functional segment is compared with the compensation heat already allocated to the corresponding segment in the heat compensation scheme. A functional segment with an allowable compensable heat lower than the allocated amount indicates that the original allocation amount exceeds the safety boundary and needs to be compressed to within the allowable compensable heat. The greater the compression, the more significant the deviation between the original allocation scheme and the actual safety boundary in the heat compensation scheme for that segment. In a homogenization section, the plasticized compound has a high degree of plasticization and a low critical temperature. The wall temperature margin corresponding to the upper limit of the compensation threshold is small, and the allowable compensation heat is significantly lower than the original allocation in the heat compensation scheme. The upper limit of the speed adjustment corresponding to the segmented control threshold of this section is adjusted downward, and the upper limit of shear heat generation is reduced accordingly. The actual compensation heat is strictly controlled within the allowable compensation heat. In a compression section, the margin between the reference wall temperature and the upper limit of the compensation threshold is large, and the allowable compensation heat is sufficient. The segmented control threshold maintains the original allocation parameters in the heat compensation scheme. The contrast between the loose control upper limit of the compression section and the tight control upper limit of the homogenization section is clearly reflected in the segmented control threshold. The upper limit of speed adjustment and the upper limit of wall temperature adjustment corresponding to the allowable compensation heat of each functional section are parallel along the screw axis, which are the segmented control thresholds. The adjacent sections with greater differences in the upper limit parameters within the threshold need to be more precisely distinguished in process adjustment to avoid applying over-limit compensation to functional sections with insufficient margin.

[0051] Step S14: Based on the segmented control threshold, the barrel temperature and screw speed are adjusted according to the segmented plasticizing process plan to generate process adjustment records. Based on the process adjustment records, the back pressure fluctuation of the die head is verified to generate back pressure fluctuation data. Through the back pressure fluctuation data, the back pressure stabilization zone is confirmed to generate a uniform plasticizing value.

[0052] Specifically, based on the segmented control thresholds, the barrel temperature and screw speed are adjusted according to the segmented plasticizing process plan to generate process adjustment records. The upper limit of speed adjustment and the upper limit of wall temperature adjustment for each functional segment in the segmented control thresholds serve as the boundary constraints for this adjustment. The adjustment parameters corresponding to each insufficiently plasticized segment in the segmented plasticizing process plan are issued segment by segment within the constraints of the segmented control thresholds. The wall temperature adjustment command takes the target wall temperature of each segment as the final value and the current measured wall temperature as the starting point, and proceeds at a linear climbing rate. The climbing rate is jointly determined by the wall temperature margin of the corresponding segment in the segmented control thresholds and the thermal response rate of the rubber compound. The smaller the margin, the more conservative the climbing rate to prevent the wall temperature from exceeding the limit. The screw speed adjustment command is applied segment by segment according to the speed reduction range corresponding to each insufficiently plasticized segment. The speed reduction range is calculated based on the severity of insufficient plasticization in that segment in the segmented plasticizing process plan. The reduction range is larger for severely short-supply segments and smaller for moderately short-supply segments. After the adjustment command is issued, each functional segment collects the wall temperature response and speed execution status in real time. The wall temperature response is read hourly using thermocouple array measuring points, and the speed execution status is collected using encoder signals from the screw drive motor. The two sets of execution data are paired hourly with the corresponding adjustment command values. The pairing results are aggregated into a process adjustment record using functional segment numbers and time markers as dual indexes. The difference between the rise rate of the wall temperature response curve in each segment and the linear rise rate of the adjustment command in this record reflects the actual response capability of the heating element in that segment. After long-term high-temperature operation, the surface of the heating belt in a certain compression segment oxidizes, leading to increased contact thermal resistance. The rise rate of the wall temperature response curve is significantly lower than the commanded rise rate. The process adjustment record shows an execution lag characteristic in this segment, indicating that the heating element needs to be repaired or replaced. In a certain homogenization segment, the screw drive system has insufficient speed loop gain in the low-speed range. The speed execution curve shows obvious sawtooth jitter near the commanded value. The process adjustment record shows that the speed deviation in this segment is consistently large, indicating that the drive control parameters need to be readjusted.

[0053] In some embodiments, the step of verifying the back pressure fluctuation of the die head based on the process adjustment record to generate back pressure fluctuation data includes: extracting spontaneous back pressure fluctuation data during a constant screw speed period from the process adjustment record to form a constant speed segment back pressure fluctuation record; calculating the spontaneous back pressure fluctuation amplitude for each period of the constant speed segment back pressure fluctuation record to form a residual fluctuation curve; confirming the continuously shrinking fluctuation amplitude segment based on the residual fluctuation curve to form a homogenization process curve; and verifying the back pressure fluctuation amplitude based on the homogenization process curve to generate back pressure fluctuation data.

[0054] The back pressure spontaneous fluctuation data during constant screw speed periods in the process adjustment records are extracted to form a constant speed segment back pressure fluctuation record. The screw speed execution curve in the process adjustment records is checked hourly. Periods where the speed execution value deviates from the target speed by less than the speed control accuracy threshold within several consecutive acquisition intervals are defined as constant speed periods. The determination of constant speed periods excludes brief overshoot caused by mechanical inertia during speed adjustment transitions, retaining only the pure spontaneous fluctuation stage where the screw operates stably and the speed's impact on back pressure is negligible. The readings of the die head inlet pressure sensor 16 corresponding to each constant speed period in the process adjustment records are extracted hourly. Sensor 16 is installed at the inlet section of the die head 12, and the readings are in absolute pressure units. The extracted back pressure time-series data, along with the start and end time markers of the corresponding constant speed period, are included in the constant speed segment back pressure fluctuation record. After the rotational speed of a certain functional segment is adjusted downward from a higher level, it enters a constant speed period. During this period, the back pressure of the die head exhibits significant initial fluctuations due to the incomplete stabilization of the rubber compound filling state. The fluctuation amplitude gradually narrows over time, and the back pressure time series curve in the constant speed segment back pressure fluctuation record shows a transition from wide-amplitude oscillations to narrow-amplitude oscillations. In another functional segment, if the rotational speed adjustment is smaller, the initial back pressure fluctuation amplitude during the constant speed period is inherently smaller, and the back pressure time series curve in the constant speed segment back pressure fluctuation record is generally stable. These two types of patterns coexist in the constant speed segment back pressure fluctuation record, reflecting the different effects of different adjustment amplitudes on the stability rhythm of the die head back pressure. The back pressure time series data for all constant speed periods in the constant speed segment back pressure fluctuation record are arranged in time-marked order, with the start and end boundaries of each period marked by the start and end times determined by the constant rotational speed.

[0055] For back pressure fluctuation records in the constant speed range, the spontaneous fluctuation amplitude of back pressure at each time period is calculated to form a residual fluctuation curve. In the back pressure fluctuation records of the constant speed range, the back pressure time series data for each constant speed period are calculated point-by-point within a fixed sliding window. The range R_w is defined as the difference between the maximum and minimum back pressure values ​​within the window: R_w = P_max - P_min, where P_max and P_min are both in MPa, and R_w is in MPa. A larger R_w indicates a higher spontaneous fluctuation amplitude of back pressure before and after that moment in a short period, while a smaller R_w indicates that the back pressure tends to be stable within the window. The width of the sliding window for the back pressure fluctuation records in the constant speed range is determined based on an integer multiple of the screw's single-turn propulsion time. The window covers an integer number of screw rotation cycles, eliminating the influence of periodic disturbances in the screw groove on the range calculation, ensuring that the R_w sequence only reflects the spontaneous fluctuations caused by the uniformity of plasticization of the rubber compound. In a certain functional segment, during the initial period of constant rotational speed, R_w is relatively large, and the R_w sequence continuously narrows over time, with the residual fluctuation curve showing a monotonically decreasing trend during this period. In another functional segment, if R_w is already relatively small at the beginning, the residual fluctuation curve is generally stable during this period, with isolated high values ​​appearing only at individual sampling moments before falling back. These two types of patterns are clearly distinguishable in the residual fluctuation curve. The former indicates that the plasticization state gradually stabilizes after adjustment, while the latter indicates that the plasticization state was basically uniform before adjustment. The R_w sequences of each constant rotational speed period are connected sequentially along the time markers to form the residual fluctuation curve. In the curve, the interval where the R_w sequence continuously decreases from a high value corresponds to the gradual improvement of plasticization uniformity as adjustment progresses, while the interval where the R_w sequence remains stable at a low value corresponds to the plasticization state becoming uniform.

[0056] Based on the residual fluctuation curve, the homogenization process curve is formed in the segment where the fluctuation amplitude continuously decreases. The R_w sequence in the residual fluctuation curve is examined time-by-time. The period in which the R_w value monotonically decreases within several consecutive acquisition intervals and the decrease in each interval is higher than the noise level of the R_w sequence is defined as the segment where the fluctuation amplitude continuously decreases. The noise level is estimated by the standard deviation of the R_w sequence in the low-value stable phase of the residual fluctuation curve. The determination of the continuously decreasing segment distinguishes the actual homogenization process from the random jitter of the R_w sequence near the low value. The starting point of the continuously decreasing fluctuation amplitude segment corresponds to the moment when the plasticization uniformity of the rubber begins to improve, and the ending point corresponds to the moment when the R_w sequence stops monotonically decreasing and enters a low-value stable stage. After the speed adjustment of a certain functional segment is completed, the continuously decreasing fluctuation amplitude segment appears only after a delay of several sampling intervals. The delay time corresponds to the hysteresis of the rubber's thermal-fluid response to the speed adjustment. The shorter the hysteresis time, the more sensitive the response of the rubber to the process parameter adjustment in that segment. If the R_w sequence directly enters a low-value stable stage after the speed adjustment of another functional segment without the continuous decreasing segment, it indicates that the plasticization state of that segment was already at a uniform level before the adjustment. The start and end times of the continuously decreasing fluctuation amplitude segment and the start and end values ​​of the R_w sequence in the corresponding time period are integrated according to the time mark order to form the homogenization process curve. The longer the span of each continuously decreasing segment in the curve, the slower the homogenization process of the rubber in that segment. The shorter the span, the faster the homogenization process. The difference between the start and end values ​​of R_w in each segment reflects the improvement in the plasticization uniformity of the rubber in that segment during the entire homogenization process.

[0057] Back pressure fluctuation data is generated by verifying the back pressure fluctuation amplitude based on the homogenization process curve. At the end of each continuously decreasing fluctuation amplitude segment in the homogenization process curve, the corresponding R_w sequence enters a low-value stable phase. The average R_w sequence value during this low-value stable phase is used as the steady-state back pressure fluctuation amplitude under the current adjustment conditions of that functional segment. The lower the steady-state back pressure fluctuation amplitude, the higher the plasticization uniformity of the rubber compound under the process parameters of that segment, and the smaller the spontaneous disturbance of the die head back pressure under this state. If the R_w sequence shows a phased rebound after the continuous decreasing fluctuation amplitude segment in the homogenization process curve ends in the low-value stable phase, it indicates that the plasticization state of this functional segment has been subjected to new disturbances after stabilizing. The source of the disturbance is usually related to batch-to-batch differences in the rubber compound formulation or that the upstream functional segment adjustment has not yet fully stabilized. The difference between the magnitude of the phased rebound and the average value of the low-value stable phase in the homogenization process curve reflects the intensity of this disturbance. In a homogenization process curve, the R_w sequence during the low-value stable phase of a certain homogenization section remained at a low level for a long time, only briefly rising and then quickly falling back during batch switching of rubber compounds. The steady-state back pressure fluctuation amplitude was only slightly affected by batch switching. In a compression section, the average R_w value during the low-value stable phase was significantly higher than that in the homogenization section, indicating that the plasticization uniformity of the rubber compound in the compression zone was still lower than that in the homogenization section under the current process adjustment conditions. The difference in steady-state back pressure fluctuation amplitude between the two sections was reflected in the back pressure fluctuation data as an axial distribution pattern of higher values ​​in the compression section and lower values ​​in the homogenization section. The steady-state back pressure fluctuation amplitude of each functional section in the homogenization process curve is listed sequentially along the screw axis to form the back pressure fluctuation data. When the data is generally high, it indicates that there is still considerable room for improvement in the plasticization uniformity of the current batch of rubber compound across the entire screw section. When the back pressure fluctuation data is prominent in a local section, it suggests that there is an independent cause of plasticization inhomogeneity in that section.

[0058] In some embodiments, the step of generating a plasticizing uniformity value by confirming the back pressure stabilization segment through the back pressure fluctuation data includes: distinguishing between instantaneous fluctuations and continuous fluctuations in the back pressure oscillation to form a back pressure fluctuation type proportion; confirming that the proportion of instantaneous fluctuations in the back pressure fluctuation type proportion continuously increases to form a back pressure stabilization segment; performing a steady-state duration test on the back pressure stabilization segment to form a steady-state verification result; and performing a plasticizing uniformity assessment based on the steady-state verification result to generate a plasticizing uniformity value.

[0059] The back pressure fluctuation data is differentiated into instantaneous and continuous fluctuations to determine the proportion of back pressure fluctuation types. The steady-state back pressure fluctuation amplitude time series curves of each functional segment in the back pressure fluctuation data are classified according to the duration of the fluctuation. An event in which the back pressure deviates from the low stable average value and exceeds the threshold within a single acquisition interval, and then falls back to within the threshold in the next acquisition interval, is defined as an instantaneous fluctuation. An event in which the back pressure deviates from the average value and exceeds the threshold for two or more consecutive acquisition intervals, and the duration spans multiple intervals, is defined as a continuous fluctuation. Instantaneous fluctuations usually originate from local rubber agglomeration or brief air entrapment in the screw channel, while continuous fluctuations are usually related to intermittent flow pulsations caused by uneven plasticization. The causes and adjustment response modes of the two types of fluctuations are different. In the back pressure fluctuation data, the number of instantaneous fluctuation events and the number of continuous fluctuation events in each functional segment within the statistical period are counted separately. The proportion of each type of event to the total number of fluctuation events is used to synthesize the back pressure fluctuation type proportion. A higher proportion of instantaneous fluctuations indicates that the back pressure oscillations in that period are mainly caused by short-term disturbances, and the overall plasticization uniformity is better. A higher proportion of continuous fluctuations indicates that the rubber flow pulsation is more prominent, and the plasticization uniformity has not yet reached a stable level. In a certain homogenization segment, after the process adjustment stabilizes, the proportion of instantaneous fluctuations continues to increase while the proportion of continuous fluctuations decreases simultaneously, showing an evolution trend where the proportion of back pressure fluctuation types is dominated by instantaneous fluctuations. In a certain compression segment, the proportion of continuous fluctuations remains at a high level for a long time, and the proportion of back pressure fluctuation types in this segment shows a pattern dominated by continuous fluctuations. The distribution of the proportion of back pressure fluctuation types in the two segments forms a sharp contrast in the back pressure fluctuation data comparison. The proportion of back pressure fluctuation types is updated periodically by statistical period. The proportions of instantaneous fluctuations and continuous fluctuations in each period are arranged in time-marked order, forming a dynamic evolution of the proportions as the adjustment progresses.

[0060] The continuously rising proportion of instantaneous fluctuations within the back pressure fluctuation type was identified as forming a back pressure stabilization zone. The proportion of instantaneous fluctuations within the back pressure fluctuation type time series was examined period by period. Periods where the proportion of instantaneous fluctuations monotonically increases while the proportion of continuous fluctuations decreases synchronously over several consecutive statistical periods were defined as candidate stabilization periods. The determination of a candidate stabilization period required that the changes in the two types of proportions were consistent, excluding isolated interference such as occasional single-period increases in the proportion of instantaneous fluctuations without a synchronous decrease in the proportion of continuous fluctuations. The starting statistical period of the candidate stabilization period corresponds to the moment when continuous fluctuations begin to transform into instantaneous fluctuations. The earlier the starting time, the more rapidly the plasticization uniformity of the batch of rubber compound improved after process adjustments. The stabilization candidate period for a certain functional segment begins within several statistical cycles after the speed adjustment is completed. The proportion of persistent fluctuations drops rapidly during this segment, while the proportion of instantaneous fluctuations rises simultaneously. The crossover point of these two types of proportions is clearly visible in the time series of back pressure fluctuation type proportions. After the crossover, the proportion of instantaneous fluctuations continues to rise until it becomes dominant. In another functional segment, the two types of proportions fluctuate alternately for a long time without a stable unidirectional evolution trend, indicating that the plasticization state in this segment is difficult to sustainably stabilize under the alternating influence of multiple disturbance factors. The criteria for determining the stabilization candidate period are repeatedly triggered in this segment, resulting in multiple short-lived candidate periods without a sustained segment. All stabilization candidate periods that meet the criteria are merged in time-marked order to form the back pressure stabilization segment. The start and end times of each candidate period within this segment, along with the change in the proportion of instantaneous fluctuations within the corresponding period, are recorded together. The larger the change, the more significant the improvement in plasticization uniformity within the candidate period.

[0061] Steady-state duration verification is performed on the back pressure stabilization zone to generate steady-state verification results. The number of consecutive statistical periods for each candidate time period within the back pressure stabilization zone is used as the raw measure of steady-state duration. The longer the steady-state duration, the more stable the back pressure stabilization state corresponding to that candidate time period is. Candidate time periods that appear briefly and then are interrupted have short steady-state durations, and the degree of stabilization of the corresponding plasticizing state is questionable. The steady-state duration verification uses the median of the steady-state duration of all candidate time periods within the back pressure stabilization zone as the verification benchmark. Candidate time periods with a duration lower than a certain proportion of the median are judged as insufficiently sustained. Candidate time periods with insufficient sustained duration indicate that although the plasticizing state of that section has briefly stabilized, it has failed to be maintained, and may have been interrupted prematurely due to fluctuations in upstream rubber supply or periodic disturbances in the screw compressor. Candidate time periods with a duration higher than the median are judged as having sufficient steady-state duration. In a certain homogenization section, the steady-state duration of the main candidate periods in the back pressure stabilization zone far exceeded the median, confirming that the steady-state verification result for this section was sufficiently stable. In a certain compression section, the steady-state duration of multiple candidate periods was below the median, with the steady-state verification results showing a general lack of persistence. This indicates that the plasticization state in the compression section has a weaker ability to stabilize under the current adjustment conditions, and the sustainability of the improvement in plasticization homogeneity is lower than that in the homogenization section. The steady-state duration and verification conclusions of each candidate period in the back pressure stabilization zone are recorded in time-marked order as the steady-state verification results. The ratio of sufficiently stable to insufficiently stable candidate periods reflects the plasticization stabilization ability of the current batch of rubber compound under the overall adjustment state.

[0062] Plasticization uniformity is assessed and a plasticization uniformity value is generated based on the steady-state verification results. The average proportion of instantaneous fluctuations in the fully stable candidate periods in the steady-state verification results serves as the main basis for plasticization uniformity assessment. A higher average proportion of instantaneous fluctuations and a lower average proportion of continuous fluctuations during the stabilization process of a fully stable candidate period indicate that the rubber flow pulsation has been sufficiently suppressed during that period, and the die head back pressure oscillation is mainly composed of acceptable short-term local disturbances, indicating a high level of plasticization uniformity. The plasticization uniformity value UI is calculated as a weighted average of the average proportions of instantaneous fluctuations in all fully stable candidate periods in the steady-state verification results: UI = Σ(w_i × ρ_i) / Σw_i, where ρ_i is the average proportion of instantaneous fluctuations in the i-th fully stable candidate period (dimension 1), w_i is the proportion of the steady-state duration of that candidate period to the total duration of all fully stable candidate periods (dimension 1), and UI is dimension 1. The closer UI is to 1, the higher the degree of plasticization uniformity; the lower UI is, the higher the proportion of continuous fluctuations in the steady-state period. In a certain homogenization segment, the duration of a sufficiently stable candidate period is long and the ρ_i is high. This segment has a significant contribution weight to the plasticization homogenization value and raises the UI. In a certain compression segment, the duration of a sufficiently stable candidate period is short and the ρ_i is also low. This segment has a small contribution weight and lowers the UI. The difference in contribution between the two segments in the evaluation of plasticization homogenization value directly reflects the uneven spatial distribution of plasticization homogenization degree in each functional segment. When the number of sufficiently stable candidate periods in the steady-state verification results is zero, the plasticization homogenization value is downgraded and assigned a score based on the longest-lasting candidate period ρ_i in the back pressure stabilization zone. The downgraded score is lower than the normal evaluation value, reflecting that the plasticization homogenization degree under the current regulation state has not yet reached the sufficiently stable standard.

[0063] Step S15: Based on the plasticization uniformity value, reverse the flow block throttling gap of the die head to generate a flow block throttling gap adjustment scheme, and execute the die head pressure adjustment to output extrusion molding control command according to the flow block throttling gap adjustment scheme.

[0064] Specifically, a throttling gap adjustment scheme for the throttling block is generated by back-calculating the plasticization uniformity value. The plasticization uniformity value quantifies the overall plasticization uniformity of the current rubber compound by the weighted average of the instantaneous fluctuation ratios of the fully stable candidate periods of each functional segment. A higher plasticization uniformity value indicates a more consistent flow state of the rubber compound and a more uniform pressure distribution at the inlet section of the die head 12. In this case, the throttling gap of the throttling block 13 can be appropriately widened to reduce extrusion resistance. When the plasticization uniformity value is low, the flow uniformity of the rubber compound is poor, and there is obvious circumferential unevenness in the pressure distribution at the die head inlet section. It is necessary to narrow the throttling gap of the throttling block to increase the back pressure and use the back pressure homogenization effect to compensate for the flow pulsation at the screw outlet. The correspondence between the throttling gap of the throttling block and the plasticization uniformity value is determined by the rheological characteristics of the rubber compound formulation. The rheological characteristics are based on the Mooney viscosity range of the formulation and the shear thinning index at the corresponding temperature. The back-calculation of the throttling gap is constrained by the target extrusion pressure range, and the optimal throttling gap is the gap value that maximizes the uniformity of the pressure distribution at the die head section. When the plasticizing uniformity of a batch is significantly low, the gap narrowing command in the throttling gap adjustment scheme of the flow choke block covers all adjustment units; when the plasticizing uniformity is close to the full value, the gaps of each unit in the throttling gap adjustment scheme of the flow choke block are widened and the differences are narrowed, reflecting that the demand for flow choke action in all directions of the uniform incoming flow tends to be consistent. The target throttling gap value of each throttling block adjustment unit and the unit number are registered one by one along the circumference of the die head to form the throttling gap adjustment scheme of the flow choke block. In the scheme, the lower the plasticizing uniformity of the batch, the greater the difference in the target gaps of each unit and the more uneven the circumferential distribution.

[0065] The extrusion molding control command is executed based on the throttling gap adjustment scheme of the flow choke block. The target gap values ​​of each adjustment unit in the flow choke block throttling gap adjustment scheme are sequentially sent to the servo drive mechanism 14 of the flow choke block 13 inside the die head 12. The actual gap of each unit is fed back in real time by the displacement sensor 15. The difference between the actual gap and the target gap constitutes the execution deviation of that unit. When the execution deviation exceeds the limit, the servo drive mechanism advances the compensation action in a small-step, multiple-approach manner to avoid sudden pressure changes inside the die head caused by a single adjustment. After each adjustment unit is in place, the die head inlet pressure sensor 16 continuously collects pressure data at several intervals. The average value is compared with the target pressure range corresponding to the flow choke block throttling gap adjustment scheme. If the measured average pressure is too high, it indicates that the narrowing of the throttling gap exceeds expectations; if the measured average pressure is too low, it indicates that the widening exceeds expectations. Both types of deviations trigger the gap fine-tuning of the corresponding unit. The fine-tuning amount is determined by dividing the difference between the measured pressure and the target range boundary by the pressure-gap sensitivity coefficient of the formula. The fine-tuning direction is opposite to the deviation direction. A certain high-viscosity formulation batch had a higher sensitivity coefficient. The single-step gap fine-tuning amount was compressed to a fraction of that of the regular batch. After multiple small fine-tunings, the gap gradually approached the target pressure range, avoiding overshoot and rebound of the high-viscosity compound on the die head pressure. A certain low-viscosity formulation batch had a lower sensitivity coefficient. The gap could reach the target value in one step with a larger step size. The adjustment accuracy adaptively converged with changes in the rheological properties of the formulation. After the die head pressure adjustment verification was passed, the current actual gap value of each unit, the average measured pressure at the die head inlet, and the current screw speed together constituted the current extrusion state parameter set. The extrusion molding control command was based on the current extrusion state parameter set, superimposed with molding parameters such as die opening, traction speed, and cooling section length. Each molding parameter was arranged according to parameter number to form the extrusion molding control command and sent to the actuators such as die 17. The execution feedback value returned by each actuator was checked against the command value parameter by parameter. After all parameters were checked and passed, the extrusion molding control command was confirmed to have been executed.

[0066] To implement the automated continuous extrusion rubber-based soft liner production method corresponding to the above method embodiments, in order to achieve the corresponding functions and technical effects. See also Figure 3 , Figure 3 This application provides a structural block diagram of an automated continuous extrusion rubber-based soft liner production apparatus 300, comprising: The data acquisition unit 301 is used to acquire Mooney viscosity data and barrel wall temperature distribution data of the rubber base compound to be extruded, and to perform correlation verification on the Mooney viscosity data and the wall temperature distribution data to generate a viscosity-temperature consistency index. Plasticization evaluation unit 302 is used to evaluate the temperature difference distribution of the wall temperature distribution data to generate a segmented plasticization progress distribution, measure the axial temperature difference between the feeding section, compression section and homogenization section from the wall temperature distribution data to generate the inter-segment temperature difference gradient, and determine the insufficient plasticization section based on the segmented plasticization progress distribution and the inter-segment temperature difference gradient to construct a segmented plasticization process scheme. The compensation decision unit 303 is used to conduct segmented viscosity deviation assessment based on the viscosity-temperature consistency index and the segmented plasticizing process scheme to generate a viscosity deviation distribution, redistribute the cross-segment heat margin of the viscosity deviation distribution to generate a heat compensation scheme, and implement heat-oriented compensation to establish segmented control thresholds based on the heat compensation scheme. The extrusion control unit 304 is used to adjust the barrel temperature and screw speed according to the segmented control threshold to generate a process control record for the segmented plasticizing process scheme, verify the back pressure fluctuation of the die head based on the process control record to generate back pressure fluctuation data, and confirm the back pressure stabilization zone through the back pressure fluctuation data to generate a plasticizing uniform value. The molding output unit 305 is used to generate a throttling gap adjustment scheme for the throttling gap of the die head based on the plasticizing uniformity value, and to execute the die head pressure adjustment and output extrusion molding control command according to the throttling gap adjustment scheme.

[0067] The aforementioned automatic continuous extrusion rubber-based soft liner production apparatus 300 can implement the automatic continuous extrusion rubber-based soft liner production method of the above method embodiments. The options in the above method embodiments are also applicable to this embodiment, and will not be detailed here. The remaining contents of this application's embodiments can be referred to the contents of the above method embodiments, and will not be repeated in this embodiment.

[0068] The purpose of the above embodiments is to reproduce and derive the technical solution of the present invention by way of example, and to fully describe the technical solution, purpose and effect of the present invention. The purpose is to enable the public to have a more thorough and comprehensive understanding of the disclosure of the present invention, and not to limit the scope of protection of the present invention.

Claims

1. An automatic continuous extrusion method for producing rubber-based soft liners, characterized in that, include: Collect Mooney viscosity data of the rubber-based compound to be extruded and barrel wall temperature distribution data, and perform correlation verification on the Mooney viscosity data and the wall temperature distribution data to generate viscosity-temperature consistency index; The wall temperature distribution data is used to evaluate the temperature difference distribution and generate a segmented plasticizing progress distribution. The temperature difference along the axial direction of the feeding section, compression section and homogenization section is measured from the wall temperature distribution data to generate the inter-segment temperature difference gradient. Based on the segmented plasticizing progress distribution and the inter-segment temperature difference gradient, the insufficient plasticizing section is determined and a segmented plasticizing process scheme is constructed. Based on the viscosity-temperature consistency index and the segmented plasticizing process scheme, a segmented viscosity deviation assessment is carried out to generate a viscosity deviation distribution. The viscosity deviation distribution is then redistributed across segments to generate a heat compensation scheme. Based on the heat compensation scheme, heat-oriented compensation is implemented to establish segmented control thresholds. Based on the segmented control threshold, the barrel temperature and screw speed are adjusted according to the segmented plasticizing process scheme to generate process adjustment records. Based on the process adjustment records, the back pressure fluctuation of the die head is verified to generate back pressure fluctuation data. Through the back pressure fluctuation data, the back pressure stabilization zone is confirmed to generate a plasticizing uniformity value. Based on the plasticizing uniformity value, the flow obstruction block throttling gap of the die head is reversed to generate a flow obstruction block throttling gap adjustment scheme. According to the flow obstruction block throttling gap adjustment scheme, the die head pressure is adjusted and the extrusion molding control command is output.

2. The method according to claim 1, characterized in that, The step of performing correlation verification between the Mooney viscosity data and the wall temperature distribution data to generate a viscosity-temperature consistency index includes: Based on the Mooney viscosity data and the wall temperature distribution data, the viscosity change lag time and temperature change time of adjacent segments are determined to form the inter-segment response lag difference; The inter-segment response hysteresis difference is statistically analyzed for each segment according to the screw section to form the inter-segment hysteresis difference gradient; Based on the inter-segment hysteresis gradient, the hysteresis exceeding the baseline section is determined to form the inter-segment process mismatch section; A viscosity-temperature consistency index is formed based on the correlation between the inter-segment process mismatch zone and the wall temperature distribution data.

3. The method according to claim 1, characterized in that, The step of determining insufficiently plasticized segments and constructing a segmented plasticizing process scheme based on the segmented plasticizing progress distribution and the inter-segment temperature gradient includes: The flow state parameters of the rubber compound in each segment are recorded to form the plasticizing flow characteristics; The plasticizing flow characteristics were compared with the inter-segment temperature gradient to confirm the screw material slippage zone. For the slippage section of the screw, verify the continuity of the rubber flow and confirm the insufficient plasticization section; A segmented plasticizing process scheme is constructed based on the distribution characteristics of the insufficiently plasticized segments.

4. The method according to claim 1, characterized in that, The step of redistributing the viscosity deviation distribution across segments of the heat margin to generate a heat compensation scheme includes: The viscosity deviation distribution is checked to determine the deviation level of each segment, forming an inter-segment deviation distribution. The heat reserve of each segment is extracted from the inter-segment deviation distribution to form a heat reserve distribution; Based on the aforementioned heat surplus distribution, the cross-section heat replenishment demand is assessed to form a cross-section heat replenishment demand comparison; A heat compensation scheme is generated by redistributing cross-segment shear heat based on the cross-segment heat replenishment demand comparison.

5. The method according to claim 1, characterized in that, The step of establishing segmented control thresholds by implementing thermal directional compensation based on the aforementioned thermal compensation scheme includes: Based on the aforementioned thermal compensation scheme, the implementation status of thermal compensation for each segment is summarized to form a compensation implementation record; The compensation execution record is used to screen for the second viscosity increase segment to form an overcompensated section; Perform a unit heat temperature rise decay analysis on the overcompensated section to confirm the upper limit of the compensation threshold; Based on the upper limit of the compensation threshold, the allowable compensation heat for each segment is calculated to establish the segmented control threshold.

6. The method according to claim 1, characterized in that, The process of generating back pressure fluctuation data based on the process adjustment record verification head back pressure fluctuation includes: The back pressure spontaneous fluctuation data during the constant screw speed period is extracted from the process adjustment record to form a constant speed segment back pressure fluctuation record; For the back pressure fluctuation record of the constant speed segment, the amplitude of spontaneous back pressure fluctuation in each time period is calculated to form a residual fluctuation curve; Based on the residual fluctuation curve, it is confirmed that the segment where the fluctuation amplitude continues to shrink forms a homogenization process curve. Back pressure fluctuation data is generated by verifying the back pressure fluctuation amplitude based on the homogenization process curve.

7. The method according to claim 1, characterized in that, The step of confirming the generation of a uniform plasticizing value in the back pressure stabilization zone through the back pressure fluctuation data includes: The back pressure fluctuation data is used to distinguish between instantaneous fluctuations and continuous fluctuations in back pressure oscillations to form the proportion of back pressure fluctuation types; It was confirmed that the segment in which the proportion of instantaneous fluctuations in the back pressure fluctuation type continuously increased formed a back pressure stabilization segment. The steady-state duration of the back pressure stabilization zone is tested to generate a steady-state verification result; Based on the steady-state verification results, plasticization uniformity is evaluated to generate a plasticization uniformity value.

8. The method according to claim 3, characterized in that, The verification of the continuity of rubber flow and confirmation of insufficient plasticization in the slippage section of the screw rubber includes: Based on the recorded pressure recovery status of each section of the screw rubber slippage zone, a pressure recovery record is formed. The pressure recovery rate of each segment is statistically analyzed to form a recovery rate distribution; Based on the aforementioned recovery rate distribution, sections with abnormally high recovery rates are identified as plasticizing short-supply sections. Based on the screening of the aforementioned plasticized short supply sections, sections with insufficient plasticization were identified.

9. The method according to claim 5, characterized in that, The step of performing a unit heat temperature rise attenuation analysis on the overcompensated section to confirm the upper limit of the compensation threshold includes: Based on the measured rubber outlet temperature and compensated input heat of each section in the overcompensated section, a unit heat temperature rise curve is formed. The decay rate distribution is formed by statistically analyzing the continuous decreasing rate of temperature rise values ​​at each level in the unit heat temperature rise curve. The abrupt change point in the attenuation rate distribution is determined to locate the inflection point of decreasing conduction efficiency. Based on the inflection point of decreasing conduction efficiency, the boundary of secondary viscosity increase is confirmed to form the upper limit of the compensation threshold.

10. An automatic continuous extrusion rubber-based soft liner production device, characterized in that, include: The data acquisition unit is used to collect Mooney viscosity data and barrel wall temperature distribution data of the rubber-based compound to be extruded, and to perform correlation verification on the Mooney viscosity data and the wall temperature distribution data to generate a viscosity-temperature consistency index. The plasticizing assessment unit is used to evaluate the temperature difference distribution of the wall temperature distribution data to generate a segmented plasticizing progress distribution, measure the axial temperature difference between the feeding section, compression section and homogenization section from the wall temperature distribution data to generate the inter-segment temperature difference gradient, and determine the insufficient plasticizing section based on the segmented plasticizing progress distribution and the inter-segment temperature difference gradient to construct a segmented plasticizing process scheme. The compensation decision unit is used to conduct segmented viscosity deviation assessment based on the viscosity-temperature consistency index and the segmented plasticizing process scheme to generate a viscosity deviation distribution, redistribute the cross-segment heat margin of the viscosity deviation distribution to generate a heat compensation scheme, and implement heat-oriented compensation based on the heat compensation scheme to establish segmented control thresholds. The extrusion control unit is used to adjust the barrel temperature and screw speed according to the segmented control threshold to generate a process control record for the segmented plasticizing process scheme, verify the back pressure fluctuation of the die head based on the process control record to generate back pressure fluctuation data, and confirm the back pressure stabilization zone through the back pressure fluctuation data to generate a plasticizing uniform value. The molding output unit is used to generate a throttling gap adjustment scheme for the throttling gap of the die head based on the plasticizing uniformity value, and to execute the die head pressure adjustment and output extrusion molding control command according to the throttling gap adjustment scheme.

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