A fully automatic plastic production line and method

Abstract

This invention relates to the technical field of plastic production, specifically to a fully automated plastic production line and method. The line includes an automatic feeding module, a mixing extrusion module, a water tank cooling module, a dehydration module, a pelletizing module, an intelligent screening module, an automatic drying module, and an intelligent control system. The water tank cooling module includes an initial cooling ramp, a water tank, an adjustable traction conveyor mechanism, and a chiller unit. A visual inspection unit is installed at the discharge port, and temperature detection units are installed in both the water tank and the pelletizing module. This invention also relates to a fully automated plastic production method, comprising the following steps: S1, automatic feeding and melt extrusion; S2, adaptive cooling and automatic conveying; S3, intelligent dehydration and pelletizing; S4, multi-stage screening and drying; S5, adaptive strip breaking and obstacle removal. This invention enables intelligent closed-loop control throughout the entire process, adaptively matching cooling conditions, improving cooling uniformity and material compatibility, precisely controlling residual moisture, and reducing the proportion of defective products.

Description

Technical Field

[0001] This invention relates to the technical field of polymer extrusion granulation, and more specifically, to a fully automated plastic production line and method. Background Technology

[0002] Polymer extrusion modification and granulation is a core process in the research and development and large-scale production of new plastic materials. The degree of automation and process control precision of the twin-screw extrusion granulation production line directly determines the performance stability, appearance quality, and overall production efficiency of the modified granules. As downstream high-end manufacturing sectors continue to increase their requirements for batch consistency of modified plastic products, and the demand for small-batch, multi-formulation R&D and trial production continues to grow, the traditional semi-automated production mode that relies on manual supervision and intervention is gradually becoming unable to meet the development needs of industrial quality improvement, efficiency enhancement, and flexible production. Achieving automated operation and intelligent control of the entire extrusion granulation process has become an important technological development direction in this field.

[0003] In the prior art, Chinese utility model patent CN210791614U discloses a convenient plastic granulation device. This device consists of an extrusion device, a cooling device, and a pelletizing device arranged in sequence. The extrusion device has a built-in feeding screw and an extrusion die with a heating structure. The cooling device includes a water tank and a hot air dehydration mechanism. The pelletizing device conveys the material strip through clamping rollers and completes pelletizing with a rotating cutter. The overall structure is simple and can reduce the production cost of small-batch sample testing. However, the cooling and dehydration links of this technical solution are both fixed structure designs. Parameters such as the cooling path of the water tank, the cooling water temperature, and the air drying intensity cannot be dynamically adjusted in real time according to changes in the material of the material strip, the wire diameter, and the ambient temperature and humidity. It is difficult to stably control the cooling uniformity of the material strip and the residual moisture on the surface, which can easily lead to an increase in the proportion of unqualified products such as powder, clumps, and metal / impurity residues, making it difficult to ensure product quality consistency. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies, such as difficulty in controlling the uniformity of material cooling and residual moisture on the surface, resulting in poor product quality consistency. This invention provides a fully automated plastic production line and method that improves the uniformity of material cooling and the stability of moisture control, reduces the proportion of defective products, and effectively ensures the consistency of product batch quality.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A fully automated plastic production line is provided, comprising an automatic feeding module, a mixing and extrusion module, a water tank cooling module, a dehydration module, a pelletizing module, an intelligent screening module, an automatic drying module, and an intelligent control system arranged sequentially along the material conveying direction; The hybrid extrusion module includes an extruder, which is equipped with a hopper, a screw extrusion assembly and a discharge port that are interconnected. The automatic feeding module transports the raw materials to the hopper. The water tank cooling module includes an initial cooling ramp, a water tank, an adjustable traction conveying mechanism, and a chiller unit. The initial cooling ramp is located below the discharge port, the water tank is located below the initial cooling ramp, the adjustable traction conveying mechanism is located in the water tank, the water tank is provided with a first water inlet and a water outlet, the top of the initial cooling ramp is provided with a second water inlet, and the first water inlet, the water outlet, and the second water inlet are all connected to the chiller unit. The dewatering module includes a conveyor belt, a purging pipe, and a blower assembly. The feed end of the conveyor belt is located at the end of the water tank away from the mixing extrusion module. The blower assembly is connected to the purging pipe, and the air outlet of the purging pipe faces the conveyor belt. The discharge end of the conveyor belt is connected to the feed end of the pelletizing module, the discharge end of the pelletizing module is connected to the feed end of the intelligent screening module, and the qualified material discharge end of the intelligent screening module is connected to the feed end of the automatic drying module. The extruder outlet is equipped with a visual detection unit for collecting images of the material strip status, and the outlet end of the water tank and the feed end of the pelletizing module are respectively equipped with temperature detection units for collecting the surface temperature of the material strip. The intelligent control system is connected to the automatic feeding module, the mixing extrusion module, the water tank cooling module, the dewatering module, the pelletizing module, the intelligent screening module, the automatic drying module, the vision inspection unit, and the temperature detection unit. The intelligent control system can be used to determine and control the immersion depth, water flow rate, and traction speed of the water tank cooling module, and / or the extrusion speed of the mixing extrusion module, based on the strip density and the strip breakage information obtained by the vision inspection unit. The intelligent control system can also be used to calculate the actual residual moisture on the strip surface based on the strip surface temperature information obtained by the temperature detection unit, combined with the initial water film mass, strip density, and the number of strips obtained by the vision inspection unit, and adjust the fan speed of the dewatering module and / or the immersion depth of the water tank cooling module based on the actual residual moisture.

[0006] In this fully automated plastic production line, after production starts, raw materials can be either taken from a coded, movable raw material storage shelf by a feeding robot and fed into the extruder hopper, or automatically metered and fed into the extruder hopper through a feeding pipe. The screw extrusion assembly then melts and mixes the raw materials, and the molten material is continuously extruded from the outlet to form strips. The extruded high-temperature strips fall onto the initial cooling slope and flow down the slope with the water flow. The water flow is buffered and acts evenly on the surface of the strips to prevent the high-temperature strips from deforming due to rapid cooling. After the strips enter the water tank, the adjustable traction conveyor supports or pulls the strips along the cooling path. The intelligent control system adjusts the height and angle of the adjustable traction conveyor according to the strip density to control the path, immersion depth, and water passage length of the strips entering the water tank. The chiller unit maintains a stable cooling water temperature through a circulating water circuit. After cooling, the strips are conveyed into the dehydration module. High-pressure airflow is blown onto the surface of the strips through the purging pipe, while negative pressure airflow adsorbs and removes surface water. During this process, the intelligent control system dynamically adjusts the speed of the fan assembly based on feedback signals from the temperature detection unit. If the residual moisture exceeds the standard, the system reduces the immersion depth of the strips and controls the water passage length to stabilize the moisture content of the strips within the target range. The dehydrated strips are then fed into the pelletizing module, where they are cut into uniform plastic pellets. The pellets then sequentially enter the intelligent screening module, and the qualified pellets after screening enter the automatic drying module for deep drying to obtain the finished pellets. Throughout the production process, the vision inspection unit monitors the continuity of the material strip at the outlet in real time. The intelligent control system can determine and control the immersion depth, water flow rate, and traction speed of the water tank cooling module, and / or the extrusion speed of the mixing extrusion module, based on the pre-calculated material strip density and the broken strip information obtained by the vision inspection unit. The intelligent control system can also calculate the actual residual moisture based on the material strip surface temperature obtained by the temperature detection unit, combined with the quantity information obtained by the vision inspection unit, the material strip density, and the preset initial water film mass of the material strip. This allows for the determination and control of the rotation speed of the fan assembly in the dewatering module, and / or the immersion depth of the water tank cooling module. This invention enables automated operation of the entire plastic extrusion granulation process, reducing quality fluctuations and efficiency losses caused by manual intervention. Simultaneously, through an adjustable cooling conveying structure and detection and control system, it improves the uniformity of material strip cooling and the stability of moisture control, reduces the proportion of defective products, effectively ensures batch-to-batch quality consistency, and improves overall production efficiency and production line adaptability.

[0007] Furthermore, the adjustable traction conveying mechanism is preferably a tracked conveying mechanism, which includes a track, a track drive motor, a front end lifting mechanism, and a rear end lifting mechanism. The track is arranged in the internal cavity of the water tank along the material conveying direction. The track drive motor is fixedly installed on the rear end lifting mechanism, and the output shaft of the track drive motor is connected to the drive roller of the track. Both the front end lifting mechanism and the rear end lifting mechanism are slidably mounted on the side wall of the water tank. Through the adjustable front end lifting mechanism and the rear end lifting mechanism, the height and tilt angle of the track in the water tank can be flexibly changed, thereby precisely controlling the immersion depth and water passage length of the material strips, adapting to modified materials with different densities and different cooling requirements under the premise of a fixed overall length of the water tank.

[0008] Furthermore, the adjustable traction conveying mechanism can be an alternative to a guide wheel type traction mechanism. The guide wheel type traction mechanism includes a material bar clamping guide wheel, a clamping cylinder, a material bar traction slider, a guide wheel slide rail, and a guide wheel slider. The material bar clamping guide wheel is located below the initial cooling slope. The clamping cylinder is kinetically connected to the material bar clamping guide wheel. A traveling slide rail is provided along the length of the side wall of the water tank. The material bar traction slider is slidably mounted on the traveling slide rail and connected to the material bar clamping guide wheel. The guide wheel slide rail is located in the internal cavity of the water tank and includes a vertical slide rail section and a horizontal slide rail section. The guide wheel slider is slidably mounted on the guide wheel slide rail. The horizontal slide rail section can be connected to the vertical slide rail section and is located at the bottom of the water tank. Employing a guide wheel-type traction conveyor structure, the material bar clamping guide wheel and traction slider work together to automatically clamp and pull the material bar, eliminating the need for manual material threading and improving the automation level of start-up and feeding. Simultaneously, the guide wheel slider, which can move along vertical and horizontal slide rails, can flexibly lift or press down the material bar, dynamically adjusting the water passage length and immersion depth, adapting to the differentiated cooling needs of material bars of different materials and wire diameters. The horizontal slide rail section located at the bottom of the water tank allows the guide wheel slider to lift and adjust the material bar from the bottom, regulating the water passage path.

[0009] Furthermore, the top of the initial cooling slope is uniformly provided with multiple cooling slope water outlets along its width. A buffer block is installed below each cooling slope water outlet. The inlet of each cooling slope water outlet is connected to the chiller unit via a branch water pipe equipped with a booster pump and a flow control valve. This branch water pipe connects to the outlet end of the water tank or to the high-temperature water zone of the extruder's cooling water tank. The buffer block on the initial cooling slope, combined with a high-temperature water source, allows the relatively high-temperature cooling water to support the freshly extruded high-temperature strips, preventing deformation and internal stress caused by rapid cooling. The buffer module also stabilizes and homogenizes the water flow, ensuring uniform water flow impact and cooling rate across multiple parallel strips. Simultaneously, the branch water pipe with booster pump and flow control valve dynamically adjusts the water flow according to the strip's operating status. During normal production, this ensures stable strip transport; in case of strip breakage, the increased flow quickly flushes away the broken strip, improving the process adaptability and fault self-handling capability of the initial cooling section.

[0010] Furthermore, a bubble-generating module is installed at the bottom of the water tank. This module is evenly arranged along the material conveying direction and consists of multiple separate sections, each independently connected to an external air path. The separate bubble-generating module at the bottom of the water tank allows bubbles to rise and break the laminar thermal boundary layer on the material surface, enhancing the heat exchange efficiency between the cooling water and the material. This improves the cooling rate and enhances the circumferential and axial cooling uniformity of the material, preventing quality defects caused by uneven local cooling. The separate, independent air supply design allows for zoned adjustment of bubble intensity along the material conveying direction, matching the changing heat exchange requirements during the material cooling process.

[0011] Furthermore, the hybrid extrusion module also includes a waste cleaning component movable to the discharge port. The waste cleaning component includes a waste tray, a scraper, a scraper rotary motor, and a scraping cylinder. The waste tray is movable below the discharge port, the scraper is positioned at the discharge port, the output shaft of the scraper rotary motor is connected to the scraper, and the output end of the scraping cylinder is connected to the scraper rotary motor. The waste cleaning component can collect defective materials and cleaning waste through the waste tray during the initial extrusion and cleaning stages, preventing waste from falling into the water tank and contaminating the cooling water. Combined with the scraper rotary motor and scraping cylinder, it can adapt to different die head structures, achieving rapid scraping and resetting, shortening the start-up transition and cleaning operation time, reducing manual intervention, and improving the automation level of the start-up and cleaning processes.

[0012] Furthermore, the intelligent screening module includes a vibrating screen, a multi-channel color sorter, a magnetic sieve, a gravity-type magnetic dot amplification module, and a discharge pipe, which are connected sequentially along the material conveying direction. The vibrating screen includes an upper screen and a lower screen. The aperture of the upper screen is the upper limit of the target particle diameter, and the aperture of the lower screen is the lower limit of the target particle diameter. The upper and lower screens are detachably connected by an electromagnetic locking structure. The multi-channel color sorter includes a first color sorting channel and a second color sorting channel. The inlet of the first color sorting channel is located downstream of the vibrating screen, and the outlet of the first color sorting channel is connected to the magnetic sieve. The magnetic sieve is connected to the gravity-type magnetic dot amplification module. The inlet of the second color sorting channel is located downstream of the gravity-type magnetic dot amplification module, and the outlet of the second color sorting channel is connected to the discharge pipe. The gravity-type magnetic dot amplification module is a vertically arranged non-magnetic pipe, and an electromagnetic heating component is provided on the outer wall of the non-magnetic pipe. Through a multi-stage series intelligent screening structure, the entire screening process is completed sequentially, including particle size classification, primary color sorting to remove discoloration, magnetic screening to remove magnetic impurities, magnetic spot amplification, and secondary color sorting to remove amplified discoloration spots. This process can simultaneously remove unqualified particles of various forms, significantly improving the purity and appearance quality of the finished particles. The gravity-type magnetic spot amplification module transforms tiny magnetic impurities that are difficult to detect with the naked eye and color sorters into obvious discoloration spots, solving the problem of removing tiny magnetic spots. The upper and lower screens are connected by an electromagnetic locking structure, which allows for quick disassembly and replacement, shortening the time spent on screen cleaning and maintenance during production changes and improving the reliability and operational efficiency of the screening process. The intelligent control system enables closed-loop management of the entire intelligent screening module. It can preset the screening parameters of the vibrating screen based on the production formula and target particle size, and simultaneously control the color identification threshold of the dual channels of the multi-channel color sorter, the magnetic separation intensity of the magnetic sieve, and the electromagnetic heating power of the gravity magnetic point amplification module. Through electromagnetic heating, the plastic around the tiny magnetic impurities is heated and discolored to form identifiable discolored spots, which are then accurately removed in conjunction with secondary color sorting. At the same time, the intelligent control system collects data on the types, proportions, and particle size distribution of non-conforming products in each screening stage in real time, dynamically adjusts the screening parameters to adapt to fluctuations in the incoming material state, and feeds the data back to the cooling, dehydration, and pelletizing processes to optimize process parameters. This achieves integrated intelligent management of particle size classification, color removal, and magnetic impurity removal, ensuring the purity and batch quality consistency of the finished particle.

[0013] Furthermore, the present invention also includes an intelligent cleaning module, which includes a cleaning air inlet pipe, a main cleaning purging pipe, a secondary cleaning purging pipe, a cleaning motor, and a cleaning heating module. A mounting base is provided on the top of the extruder. The cleaning motor is fixedly mounted on the mounting base and connected to the main cleaning purging pipe. The cleaning air inlet pipe is located on the mounting base and communicates with the main cleaning purging pipe. The cleaning motor can drive the main cleaning purging pipe and the secondary cleaning purging pipe to rotate in the hopper. The secondary cleaning purging pipe is fixed to the side wall of the main cleaning purging pipe, and the side wall of the secondary cleaning purging pipe is provided with purging holes. The cleaning heating module is encased in the outer wall of the hopper. The intelligent cleaning module, through the cleaning motor driving the main and secondary purging pipes to rotate circumferentially, and in conjunction with staggered purging needles, achieves thorough cleaning of the inner wall of the hopper without dead angles.

[0014] The intelligent control system of the present invention includes a temperature acquisition module, an evaporation water calculation module, a residual moisture benchmark calculation module, and a ash box compensation and correction module; The temperature acquisition module is used to acquire the surface temperature of the material strip collected by the temperature detection unit, obtain the average temperature of the material strip in the wet state and the average temperature of the material strip after air drying, and calculate the temperature difference between the two. The evaporation water calculation module is used to calculate the evaporation water per unit length of material strip based on the principle of thermodynamic heat balance, according to the mass of the material strip per unit length, the specific heat capacity of the material strip at constant pressure, and the temperature difference value. The residual moisture baseline calculation module is used to subtract the amount of water evaporated per unit length of material strip from the initial water film mass when the material strip exits the water source to obtain the residual moisture baseline value. The gray box compensation and correction module is used to output compensation coefficients through a pre-trained shallow neural network gray box compensation model, and to use these compensation coefficients to correct the residual moisture reference value to obtain the actual residual moisture on the surface of the material strip. This invention also provides a fully automated plastic production method, including the following steps: S1. Automatic feeding and melt extrusion: The automatic feeding module quantitatively feeds the raw material into the hopper of the mixing extrusion module. After being melted and mixed by the screw extrusion assembly, the raw material is extruded into strips from the discharge port. S2. Adaptive cooling conveying: After the material strip is buffered and cooled by the initial cooling slope, it enters the water tank. The intelligent control system adjusts the position of the adjustable traction conveying mechanism according to the density of the material strip, and controls the immersion depth and water passage path of the material strip. S3, Intelligent Dehydration and Pelletizing: The material strip enters the conveyor belt in the dehydration module, and the blower assembly provides airflow through the purging pipe to remove the surface water of the material strip. The dehydrated material strip is then sent to the pelletizing module to be cut into pellets. S4. Multi-stage screening and drying: The granules are sequentially screened by the intelligent screening module to select qualified granules, and the qualified granules are sent to the automatic drying module to complete the drying process. S5. Adaptive obstacle removal for broken strips: The vision detection unit monitors the continuity of the material strip at the outlet in real time. When a single broken strip is detected, the intelligent control system increases the water flow rate of the initial cooling slope and increases the traction speed of the adjustable traction conveying mechanism. When multiple broken strips are detected, the intelligent control system reduces the screw speed of the screw extrusion assembly and triggers an audible and visual alarm.

[0015] Further, in step S3, the intelligent control system calculates the residual moisture on the surface of the material strip using the temperature difference method and dynamically adjusts the dehydration and cooling parameters, including: S31. Temperature acquisition and temperature difference calculation: Temperature detection units are set at the discharge end of the water tank and the feed end of the pelletizing module to collect the surface temperature of the material strips, obtain the average temperature of all material strips in the wet state and the average temperature of the material strips after air drying, and calculate the temperature difference between the two. S32. Calculate the evaporation water volume: Based on the thermodynamic heat balance principle, the evaporation water volume per unit length of the material strip is calculated according to the mass of the material strip per unit length, the specific heat capacity of the material strip at constant pressure, and the temperature difference value. S33. Calculation of residual moisture baseline value: Based on the initial water film mass when the material strip exits water, subtract the amount of water evaporated per unit length of material strip to obtain the residual moisture baseline value; S34. Gray Box Model Compensation and Correction: Using a pre-trained shallow neural network gray box compensation model, the temperature difference, material strip movement speed, ambient relative humidity, and fan component speed are input, and the compensation coefficient is output; the residual moisture baseline value is corrected using the compensation coefficient to obtain the actual residual moisture. S35. Residual Moisture Closed-Loop Control: The actual residual moisture is compared with a preset target range. If the actual residual moisture is higher than the upper limit of the preset target range, the intelligent control system increases the speed of the fan assembly; if the actual residual moisture is lower than the target lower limit, the intelligent control system decreases the speed of the fan assembly or increases the immersion depth of the material strip. S36. Target Interval Dynamic Optimization: Construct a black-box prediction model based on the random forest algorithm to predict the proportion of defective products under the corresponding working conditions. Perform traversal calculations within the feasible moisture range, select the moisture value corresponding to the minimum proportion of defective products as the target center value, and dynamically update the target range of residual moisture based on the target center value and the allowable fluctuation range.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. Adaptive matching of cooling conditions improves cooling uniformity and material compatibility. The adjustable traction conveyor mechanism flexibly adjusts the immersion depth and water path length of the strips. It can adaptively match the cooling intensity according to the differences in strip density, material, and wire diameter. Under a fixed water tank length, it can take into account the cooling needs of various modified materials. It not only ensures the uniformity of strip cooling within a single batch, but also greatly expands the range of materials applicable to the production line. 2. Precisely control residual moisture to reduce the proportion of defective products. The temperature difference between the material strip entering and leaving the drying section is collected by two temperature detection units. Based on the heat balance mechanism and ash box compensation model, the residual moisture of the material strip is accurately calculated. Based on this, the drying intensity of the fan is dynamically adjusted, and the cooling parameters such as the immersion depth of the material strip are adjusted in conjunction to achieve closed-loop precise control of residual moisture. The moisture content of the material strip is stabilized in the optimal range, thereby reducing the proportion of defective products caused by moisture fluctuations from the root cause. 3. Achieve intelligent closed-loop control throughout the entire process to ensure batch quality stability. The entire process of feeding, extrusion, cooling, pelletizing, screening, and cleaning is automated. Combined with visual strip breakage adaptive obstacle removal and process parameter self-learning functions, the interference of human operation factors on the production process is reduced. At the same time, the moisture control target is dynamically optimized through the black box prediction model, which can offset the process deviation caused by changes in environmental conditions. While improving production efficiency, it significantly ensures the consistency of product performance and appearance quality between different production batches. 4. Multi-stage screening for precise impurity removal solves the problem of removing tiny magnetic spots. Through a multi-stage series structure of vibrating screen particle size classification, dual-channel color sorting, magnetic screening, gravity magnetic spot amplification, and air screening, it can simultaneously remove various types of unqualified products such as oversized particles, discolored particles, magnetic impurities, and light dust. The gravity magnetic spot amplification module uses electromagnetic heating to heat and change the color of the plastic around tiny magnetic impurities, transforming tiny magnetic spots that are difficult to identify with the naked eye and conventional color sorting into clearly identifiable discolored spots. Combined with secondary color sorting, it achieves precise removal, effectively solving the pain point of difficult detection and removal of tiny magnetic impurities in the industry, and significantly improving the purity and cleanliness of finished granules, meeting the stringent requirements of high-end manufacturing fields for low impurity content in products. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a fully automated plastic production line. Figure 2 A schematic diagram of the waste cleaning assembly and the initial cooling ramp; Figure 3 This is a partial structural diagram of the tracked conveyor mechanism; Figure 4 This is a cross-sectional view of the tracked conveyor mechanism; Figure 5 This is a schematic diagram of the internal structure of the water removal module; Figure 6This is a structural diagram of the hopper and intelligent cleaning module; Figure 7 This is a cross-sectional view of the hopper and intelligent cleaning module; Figure 8 This is a schematic diagram of the structure of a vibrating screen. Figure 9 This is a schematic diagram of the electromagnetic locking structure; Figure 10 This is a schematic diagram of the guide wheel type traction mechanism; Figure 11 This is a schematic diagram of the water passage path for the guide wheel type traction mechanism; Figure 12 This is a schematic diagram of the water passage path in another working state of the guide wheel traction mechanism; Figure 13 This is a flowchart of a fully automated plastic production method.

[0018] In the attached diagram: 100, Automatic feeding module; 200, Mixing extrusion module; 211, Hopper; 212, Screw extrusion assembly; 213, Discharge port; 221, Waste tray; 222, Scraper; 223, Scraper rotary motor; 224, Scraper cylinder; 300, Water cooling module; 310, Initial cooling ramp; 311, Angle control mechanism; 312, Cooling ramp water outlet; 313, Buffer block; 320, Water... 321. Track; 322. Bubble manufacturing module; 330. Adjustable traction conveyor mechanism; 331. Track; 332. Track drive motor; 333. Head lifting mechanism; 334. Tail lifting mechanism; 340. Sliding seat; 350. Height adjustment track; 360. First transmission wheel; 370. Second transmission wheel; 400. Dewatering module; 410. Conveyor belt; 420. Purge pipeline; 500. Cutting... Particle module; 600, Intelligent screening module; 610, Vibrating screen plate; 611, Upper screen plate; 612, Lower screen plate; 613, Vibrating screen hook; 614, Notch; 615, Vibrating screen locking pin; 616, Spring; 617, Electromagnetic excitation magnet; 618, Vibrating screen locking hole; 620, Multi-channel color sorter; 621, First color sorting channel; 622, Second color sorting channel; 630, Gravity-type magnetic point amplification module; 6 40. Feeding pipe; 710. Material bar clamping guide wheel; 720. Clamping cylinder; 730. Material bar traction slider; 740. Guide wheel slide rail; 741. Vertical slide rail section; 742. Horizontal slide rail section; 750. Guide wheel slider; 800. Cleaning machine air inlet pipe; 810. Cleaning machine purging main pipe; 820. Cleaning machine purging secondary pipe; 821. Purging hole; 830. Cleaning machine motor; 840. Cleaning machine heating module; 850. Mounting base. Detailed Implementation

[0019] The present invention will be further described below with reference to specific embodiments. The accompanying drawings are for illustrative purposes only, representing schematic diagrams rather than actual physical objects, and should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0020] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0021] Example 1 This embodiment is the first embodiment of a fully automated plastic production line, which includes an automatic feeding module 100, a mixing extrusion module 200, a water tank cooling module 300, a water removal module 400, a pelletizing module 500, an intelligent screening module 600, an automatic drying module, and an intelligent control system arranged sequentially along the material conveying direction. The hybrid extrusion module 200 includes an extruder, which is equipped with a hopper 211, a screw extrusion assembly 212 and a discharge port 213 that are interconnected. The automatic feeding module 100 transports the raw materials to the hopper 211. The water tank cooling module 300 includes an initial cooling ramp 310, a water tank 320, an adjustable traction conveying mechanism 330, and a chiller unit. The initial cooling ramp 310 is located below the discharge port 213, the water tank 320 is located below the initial cooling ramp 310, the adjustable traction conveying mechanism 330 is located in the water tank 320, the water tank 320 is provided with a first water inlet and a water outlet, the top of the initial cooling ramp 310 is provided with a second water inlet, and the first water inlet, the water outlet, and the second water inlet are all connected to the chiller unit. like Figure 5 As shown, the dewatering module 400 includes a conveyor belt 410, a purge pipe 420, and a blower assembly. The feed end of the conveyor belt 410 is located at the end of the water tank 320 away from the mixing extrusion module 200. The blower assembly is connected to the purge pipe 420, and the air outlet of the purge pipe 420 faces the conveyor belt 410. The discharge end of the conveyor belt 410 is connected to the feed end of the pelletizing module 500, the discharge end of the pelletizing module 500 is connected to the feed end of the intelligent screening module 600, and the qualified material discharge end of the intelligent screening module 600 is connected to the feed end of the automatic drying module. The discharge port 213 is equipped with a visual detection unit for collecting images of the material strip status, and the discharge end of the water tank 320 and the feed end of the pelletizing module 500 are respectively equipped with temperature detection units for collecting the surface temperature of the material strip. The intelligent control system is connected to the automatic feeding module 100, the mixing extrusion module 200, the water tank cooling module 300, the dewatering module 400, the pelletizing module 500, the intelligent screening module 600, the automatic drying module, the vision inspection unit, and the temperature detection unit. The intelligent control system can be used to determine and control the immersion depth, water flow rate, and traction speed of the water tank cooling module 300, and / or the extrusion speed of the mixing extrusion module 200, based on the material strip density and the broken strip information obtained by the vision inspection unit. The intelligent control system can also be used to calculate the actual residual moisture on the surface of the material strip based on the surface temperature information of the material strip obtained by the temperature detection unit, combined with the initial water film quality of the material strip, the material strip density, and the number of material strips obtained by the vision inspection unit, and adjust the fan component speed of the dewatering module 400 and / or the immersion depth of the water tank cooling module 300 according to the actual residual moisture.

[0022] In this embodiment, the intelligent control system analyzes the density of raw materials, auxiliary materials, and their proportions before the material strip enters the water tank, thereby calculating the material strip density. The initial water film mass of the material strip in this embodiment is a pre-input value, determined by the type of material and the production process.

[0023] like Figure 1 , Figure 2As shown, in the fully automatic plastic production line of the present invention, after production is started, the automatic feeding module 100 conveys the raw materials to the hopper 211, the screw extrusion assembly 212 melts and mixes the raw materials, and the molten material is continuously extruded from the discharge port 213 to form strips; the extruded high-temperature strips fall onto the initial cooling slope 310, and follow the water flow down the slope, driving the strips to move towards the water tank 320. The water flow is buffered and then acts evenly on the surface of the strips to avoid rapid cooling and deformation of the high-temperature strips; after the strips enter the water tank 320, the adjustable traction conveying mechanism 330 supports or pulls the strips along the cooling path. The intelligent control system adjusts the height and angle of the adjustable traction conveying mechanism 330 according to the strip density to control the immersion depth and water passage length of the strips. The chiller unit maintains a stable cooling water temperature through the circulating water circuit. After cooling, the strip material enters the dewatering module 400 via conveyor belt 410. High-pressure airflow is blown onto the surface of the strip material through the purging pipe 420 to remove surface water. During this process, the intelligent control system dynamically adjusts the speed of the fan assembly based on feedback signals from the temperature detection unit. If the residual moisture exceeds the standard, the immersion depth of the strip material is reduced to stabilize the moisture content within the target range. The dewatered strip material is then fed into the pelletizing module 500 and cut into uniform plastic pellets. The pellets sequentially enter the intelligent screening module 600. The qualified pellets after screening enter the automatic drying module for deep drying to obtain the finished pellets. Throughout the production process, the vision detection unit monitors the continuity of the strip material at the discharge port 213 in real time. Based on feedback signals from the vision detection unit, the intelligent control system adjusts the operating parameters of the mixing extrusion module 200 and the water cooling module 300. In this embodiment, the water tank 320 employs a counter-current cooling circulation loop. Low-temperature water from the chiller unit is connected to the material discharge end of the water tank 320, while high-temperature return water flows back from the material inlet of the water tank 320 to the chiller unit. This ensures the cooling water flow direction is opposite to the material conveying direction, improving the uniformity of the cooling gradient. The conveyor belt 410 in this embodiment has a mesh-like perforated structure, facilitating downward water discharge. The purging pipe 420 is located directly above the conveyor belt 410 and includes multiple independently controllable purging branches. Pipes at corresponding positions can be selectively opened based on the number of material strips. The air outlet of the purging pipe 420 faces the upper surface of the conveyor belt 410. The fan assembly is connected to the purging pipe 420, allowing adjustment of the output airflow and pressure.

[0024] like Figure 3 , Figure 4As shown, the adjustable traction conveying mechanism 330 in this embodiment is a tracked conveying mechanism, which includes a track 331, a track drive motor 332, a front lifting mechanism 333, and a rear lifting mechanism 334. The track 331 is disposed in the internal cavity of the water tank 320 along the material conveying direction. The track drive motor 332 is fixedly installed on the rear lifting mechanism 334, and the output shaft of the track drive motor 332 is connected to the transmission roller of the track 331. The front lifting mechanism 333 and the rear lifting mechanism 334 are both slidably mounted on the side wall of the water tank 320. Through the adjustable front lifting mechanism 333 and the rear lifting mechanism 334, the height and tilt angle of the track 331 in the water tank 320 can be flexibly changed, thereby precisely controlling the immersion depth and water passage length of the material strip, and adapting to modified materials with different densities and different cooling requirements under the premise that the overall length of the water tank 320 is fixed. In this embodiment, the tail lifting mechanism 334 is a sliding seat 340. The side wall of the water tank 320 is provided with a height adjustment slide rail 350. The sliding seat 340 is connected to the height adjustment slide rail 350. The track drive motor 332 is fixed on the sliding seat 340. The output shaft of the track drive motor 332 is connected to the first transmission wheel 360. The transmission roller of the track 331 is equipped with a second transmission wheel 370. The first transmission wheel 360 and the second transmission wheel 370 are connected by belt drive.

[0025] like Figure 2As shown, in this embodiment, the top of the initial cooling slope 310 is uniformly provided with a plurality of cooling slope water outlet holes 312 along the width direction. A buffer block 313 is provided below the cooling slope water outlet holes 312. The second water inlet is connected to the chiller unit through a branch water pipe equipped with a booster pump and a flow control valve. The branch water pipe is connected to the water outlet of the water tank 320 or to the high-temperature water zone of the cooling water tank of the extruder. The water flow from the second inlet comes from the outlet of the water tank 320. At this point, the cooling water has already undergone superheat exchange with the strip, and its temperature is higher than when it flows out from the first inlet. With the buffer block 313 set on the initial cooling slope 310, it can not only use the relatively high-temperature cooling water to receive the hot strip that has just been extruded, avoiding deformation and internal stress caused by rapid cooling, but also stabilize and homogenize the water flow through the buffer module, ensuring that the water flow impact and cooling rate of multiple parallel strips are uniform. At the same time, with the branch water pipeline with booster pump and flow control valve, the water flow can be dynamically adjusted according to the strip's operating status. During normal production, it ensures stable strip delivery, and when a strip breaks, it increases the flow to quickly flush away the broken strip, improving the process adaptability and fault self-handling capability of the initial cooling section. In this embodiment, the high-temperature water zone of the cooling water tank is located in the cooling circulation water path of the extruder barrel, corresponding to the area where the cooling water collects after heat exchange between the melting and mixing section and the homogenization section of the barrel. The cooling water in this area, after heat exchange with the high-temperature barrel, typically maintains a temperature of 40℃ to 70℃, higher than the supply water temperature of the chiller unit. This allows for gradual cooling of the freshly extruded high-temperature strip, preventing internal stress and surface deformation caused by sudden cooling. In this embodiment, the initial cooling ramp 310 is made of a sheet metal part with a flat bottom, or it can be a sheet metal part with vertical grooves on its surface parallel to the direction of strip movement, to automatically straighten and arrange the strips, preventing the high-temperature strips from adhering to each other. In this embodiment, the buffer block 313 is arc-shaped, protruding from the bottom of the initial cooling ramp 310 and located below the cooling ramp outlet 312. The end of the initial cooling ramp 310 is connected to an angle control mechanism 311. The intelligent control system can adjust the height of the end of the initial cooling ramp 310 according to the obtained material density parameters through the angle control mechanism 311: when the material density is greater than the cooling water density, the end of the initial cooling ramp 310 is raised so that the material enters above the track 331; when the material density is less than the cooling water density, the end of the initial cooling ramp 310 is lowered so that the material enters below the track 331, ensuring that the material is always in contact with the track 331 and is stably pulled.

[0026] like Figure 4As shown, in this embodiment, a bubble manufacturing module 322 is provided at the bottom of the water tank 320. The bubble manufacturing module 322 is evenly arranged along the material conveying direction. The bubble manufacturing module 322 is a multi-part split structure, and each split structure is independently connected to an external air path. The split bubble manufacturing module 322 at the bottom of the water tank 320 allows bubbles to rise and break the laminar thermal boundary layer on the surface of the material strip, enhancing the heat exchange efficiency between the cooling water and the material strip, improving the cooling rate, and simultaneously improving the circumferential and axial cooling uniformity of the material strip, avoiding quality defects caused by uneven local cooling. The split-type independent air supply design allows for zoned adjustment of bubble intensity along the material conveying direction, matching the changing heat exchange requirements during the material strip cooling process. The bubble manufacturing module 322 is made of porous ceramic material, and its bottom is provided with an S-shaped flow channel, the cross-sectional area of ​​which gradually increases along the material conveying direction. The intelligent control system in this embodiment can control the bubble manufacturing module based on the material strip surface temperature collected by the temperature detection unit, controlling the heat exchange rate by adjusting the bubble discharge rate and the amount of bubbles discharged at different positions. Figure 2 As shown, the hybrid extrusion module 200 of this embodiment also includes a waste cleaning component movable to the discharge port 213. The waste cleaning component includes a waste tray 221, a scraper 222, a scraper rotary motor 223, and a scraper cylinder 224. The waste tray 221 can be moved to below the discharge port 213. The scraper 222 is located at the discharge port 213. The output shaft of the scraper rotary motor 223 is connected to the scraper 222, and the output end of the scraper cylinder 224 is connected to the scraper rotary motor 223. The waste cleaning component can receive unqualified materials and cleaning waste through the waste tray 221 during the initial extrusion and cleaning stages, preventing waste from falling into the water tank 320 and contaminating the cooling water. In conjunction with the scraper rotary motor 223 and the scraper cylinder 224, it can be adapted to different die head structures, achieving rapid scraping and resetting, shortening the operation time of start-up transition and cleaning, reducing manual intervention, and improving the automation level of start-up and cleaning processes. In this embodiment, the scraper 222 is made of copper and has a polytetrafluoroethylene coating sintered on its surface. This can prevent the high-temperature material strip from adhering to the surface of the scraper 222 and prevent damage to the die head during the scraping process.

[0027] like Figure 8 , Figure 9As shown, the intelligent screening module 600 of this embodiment includes a vibrating screen 610, a multi-channel color sorter 620, a magnetic sieve, a gravity-type magnetic amplification module 630, and a discharge pipe 640, which are connected sequentially along the material conveying direction. The vibrating screen 610 includes an upper screen 611 and a lower screen 612. The aperture of the upper screen 611 is the upper limit of the target particle diameter, and the aperture of the lower screen 612 is the lower limit of the target particle diameter. The upper screen 611 and the lower screen 612 are detachably connected by an electromagnetic locking structure. The multi-channel color sorter 620... 20 includes a first color sorting channel 621 and a second color sorting channel 622. The inlet of the first color sorting channel 621 is located downstream of the vibrating screen plate 610, and the outlet of the first color sorting channel 621 is connected to a magnetic screening machine. The magnetic screening machine is connected to a gravity-type magnetic dot amplification module 630. The inlet of the second color sorting channel 622 is located downstream of the gravity-type magnetic dot amplification module 630, and the outlet of the second color sorting channel 622 is connected to a feeding pipe 640. The gravity-type magnetic dot amplification module 630 is a vertically arranged non-magnetic pipe, and an electromagnetic heating component is provided on the outer wall of the non-magnetic pipe. Through a multi-stage series intelligent screening structure, the entire screening process is completed sequentially, including particle size classification, primary color sorting to remove discoloration, magnetic screening to remove magnetic impurities, magnetic spot amplification, and secondary color sorting to remove amplified discoloration points. This allows for the simultaneous removal of various types of unqualified particles, significantly improving the purity and appearance quality of the finished particles. The gravity-type magnetic spot amplification module 630 transforms tiny magnetic impurities, difficult to detect with the naked eye and color sorters, into obvious discoloration spots, solving the problem of removing these tiny magnetic spots. An electromagnetic locking structure is used between the upper screen plate 611 and the lower screen plate 612, enabling quick disassembly and replacement, shortening the time spent on screen cleaning and maintenance during production changes, and improving the reliability and operational efficiency of the screening process. In this embodiment, a pneumatic screening module is also installed before the feeding pipe 640. The outlet of the second color sorting channel 622 is connected to the pneumatic screening module, which is used to blow away light dust and debris from the particles. The qualified particles after screening are then fed into the automatic drying module through the feeding pipe 640. In this embodiment, the automatic feeding module 100 adopts a feeding robotic arm, and a pallet and a transfer robotic arm for transferring the pallet are provided at the end of the unloading pipe 640.

[0028] In this embodiment, the electromagnetic locking structure is an insertion structure with a notch 614: the bottom of the upper screen plate 611 is provided with a vibrating screen hook 613, and the top of the lower screen plate 612 is provided with a notch 614. When the upper screen plate 611 slides to the designated position, the vibrating screen hook 613 slides into the notch 614, and the vibrating screen locking pin 615 in the vibrating screen hook 613 is pushed by the spring 616 and inserted into the vibrating screen locking hole 618 of the lower screen plate 612 to achieve locking. The vibrating screen locking pin 615 is made of a strong magnetic material and magnetized to form a permanent magnet. When it is necessary to separate the upper screen plate 611 and the lower screen plate 612, current is applied to the electromagnetic excitation magnet 617 in the lower screen plate 612, causing the vibrating screen locking pin 615 to be pushed and compressing the spring 616, thus allowing the upper screen plate 611 to be removed.

[0029] The automatic drying module in this embodiment includes two equipment forms: the first is a mass production mode, which includes a centrifugal dewatering machine, a transition pipe and a drying storage bin connected in sequence. After centrifugal dewatering, the granules are sent to the storage bin to complete the subsequent drying; the second is a small-batch multi-batch production mode, which includes a shut-off valve, a drying tray, a tray conveying track and a drying oven. After being metered, the granules fall quantitatively into the drying tray and are sent into the drying oven by the conveying track or a robotic arm to complete the deep drying.

[0030] The intelligent control system in this embodiment includes a temperature acquisition module, an evaporation water calculation module, a residual moisture benchmark calculation module, and a ash box compensation and correction module. The temperature acquisition module is used to obtain the surface temperature of the material strip collected by the temperature detection unit, and to obtain the average temperature of the material strip in the wet state and the average temperature of the material strip after air drying, and to calculate the temperature difference between the two. The evaporation water calculation module is used to calculate the evaporation water per unit length of material strip based on the principle of thermodynamic heat balance, the mass of the material strip per unit length, the specific heat capacity of the material strip at constant pressure, and the temperature difference. The residual moisture baseline calculation module is used to calculate the residual moisture baseline value by subtracting the amount of water evaporated per unit length of material strip from the initial water film mass when the material strip exits the water. The gray box compensation and correction module is used to output compensation coefficients through a pre-trained shallow neural network gray box compensation model. The compensation coefficients are then used to correct the residual moisture baseline value to obtain the actual residual moisture on the surface of the material strip.

[0031] Example 2 This embodiment is the second embodiment of a fully automated plastic production line. This embodiment is similar to the first embodiment, except that... Figure 10 , Figure 11 , Figure 12As shown, the adjustable traction conveying mechanism 330 is a guide wheel type traction mechanism, which includes a bar clamping guide wheel 710, a clamping cylinder 720, a bar traction slider 730, a guide wheel slide rail 740, and a guide wheel slider 750. The bar clamping guide wheel 710 is located below the initial cooling slope 310. The clamping cylinder 720 is connected to the bar clamping guide wheel 710 in a transmission manner. The side wall of the water tank 320 is provided with a traveling slide rail 321 along the length direction. The bar traction slider 730 is slidably mounted on the traveling slide rail 321 and connected to the bar clamping guide wheel 710. The guide wheel slide rail 740 is located in the internal cavity of the water tank 320 and includes a vertical slide rail section 741 and a horizontal slide rail section 742. The guide wheel slider 750 is slidably mounted on the guide wheel slide rail 740. The horizontal slide rail section 742 can be connected to the vertical slide rail section 741 and is located at the bottom of the water tank 320. The system employs a guide wheel-type traction conveyor structure. The clamping guide wheel 710 and the traction slider work together to automatically clamp and pull the material strips, eliminating the need for manual material threading and improving the automation level of startup and feeding. Simultaneously, the guide wheel slider 750, which can move along vertical and horizontal slide rails, can flexibly lift or press down the material strips, dynamically adjusting the water path length and immersion depth to accommodate the differentiated cooling needs of material strips with different materials and wire diameters. In this embodiment, a photoelectric sensor is installed at the front end of the clamping guide wheel 710 to detect the entry status of the material strips. When the photoelectric sensor detects that the material strips have been in the system for a set time, the clamping cylinder 720 drives the clamping guide wheel 710 to clamp the material strips. This embodiment can adjust the position of the guide wheel slider 750 on the vertical slide rail section 741 and the horizontal slide rail section 742 to press down or lift the material strips, changing the water path length and immersion depth, and avoiding interference in the material strip movement. The guide wheel slider 750, mounted on the horizontal slide rail section 742, can slide horizontally below the vertical slide rail section 741 along the material conveying direction, providing stable support for the material from the bottom. This allows for stepless adjustment of the effective water passage length and immersion depth of the material, adapting to materials with different cooling requirements within a fixed water tank size. Furthermore, multiple sliders can be arranged in a staggered manner to create various cooling paths, improving the circumferential cooling uniformity of the material and reducing traction instability and breakage problems caused by sagging and loosening of the material.

[0032] like Figure 6 , Figure 7As shown, the fully automatic plastic production line in this embodiment also includes an intelligent cleaning module. The intelligent cleaning module includes a cleaning air inlet pipe 800, a cleaning main purging pipe 810, a cleaning secondary purging pipe 820, a cleaning motor 830, and a cleaning heating module 840. A mounting base 850 is provided on the top of the extruder. The cleaning motor 830 is fixedly installed on the mounting base 850 and connected to the cleaning main purging pipe 810. The cleaning motor 830 can drive the cleaning main purging pipe 810 and the cleaning secondary purging pipe 820 to rotate in the hopper 211. The cleaning air inlet pipe 800 is provided on the mounting base 850 and is connected to the top air inlet end of the cleaning main purging pipe 810 through a rotary sealing joint to ensure continuous air supply during the rotation of the pipe. The cleaning machine blowing auxiliary pipe 820 is fixed to the side wall of the cleaning machine blowing main pipe 810. Blowing holes 821 are set on the side wall of the cleaning machine blowing auxiliary pipe 820 through a rotating array and axial misalignment. The cleaning machine heating module 840 is wrapped around the outer wall of the hopper 211. The intelligent cleaning module drives the main and auxiliary blowing pipes to rotate circumferentially via the cleaning machine motor 830, and, in conjunction with the misaligned blowing needles, achieves thorough cleaning of the inner wall of the hopper 211 without dead angles. Combined with the cleaning machine heating module 840 wrapped around the outer wall of the hopper 211, it can heat the hopper 211 to 60-110℃, causing adhering powder materials to fall off and improving the thoroughness of cleaning powder materials. The tail end of the blowing needle is connected to a flexible pipe. When air is supplied for cleaning, the air pressure opens the flexible pipe to release air; when air supply stops, the flexible pipe closes to prevent material from entering the blowing pipe during production and causing blockage.

[0033] Example 3 This embodiment is an example of a fully automated plastic production method, such as... Figure 13 As shown, it includes the following steps: S1. Automatic feeding and melt extrusion: The automatic feeding module 100 quantitatively feeds the raw material into the hopper 211 of the mixing extrusion module 200. After being melted and mixed by the screw extrusion assembly 212, the raw material is extruded into strips from the discharge port 213. S2. Adaptive cooling conveying: After the material strip is buffered and cooled by the initial cooling ramp 310, it enters the water tank 320. The intelligent control system adjusts the position of the adjustable traction conveying mechanism 330 according to the density of the material strip, and controls the immersion depth and water passage path of the material strip. S3, Intelligent Dehydration and Pelletizing: The strip enters the conveyor belt 410 in the dehydration module 400. The fan assembly provides airflow through the purging pipe 420 to remove the surface water of the strip. The dehydrated strip is then sent to the pelletizing module 500 to be cut into pellets. S4. Multi-stage screening and drying: The granules are sequentially screened by the intelligent screening module 600 to select qualified granules, and the qualified granules are sent to the automatic drying module to complete the drying. S5. Adaptive obstacle removal for broken strips: The vision detection unit monitors the continuity of the strip at the discharge port 213 in real time. When a single broken strip is detected, the intelligent control system increases the water flow rate of the initial cooling slope 310 and increases the traction speed of the adjustable traction conveyor 330. When multiple broken strips are detected, the intelligent control system reduces the screw speed of the screw extrusion assembly 212 and triggers an audible and visual alarm.

[0034] In this embodiment, the specific process of broken strip identification and hierarchical control by the visual detection unit is as follows: The visual detection unit acquires images of the material strips at the discharge port 213 at fixed intervals and performs image processing in sequence: the color image is converted into a grayscale image, Gaussian filtering is used to remove high-frequency noise, a binary image is obtained through adaptive threshold segmentation, the outline holes of the material strip are filled through morphological closing operation, and the outline of each material strip is extracted through connected component analysis; a unique identifier is assigned to each material strip, and continuous inter-frame matching is performed based on the center point position of the outline. If a material strip does not have a valid outline detected in multiple consecutive frames, it is determined to be a broken strip.

[0035] This embodiment also employs a graded control strategy: when a single strip breakage is detected, the intelligent control system increases the water flow rate of the initial cooling ramp 310 and simultaneously increases the traction speed of the traction conveyor mechanism. After a set duration, the continuity of the strip is detected again. If it recovers, the parameters are gradually adjusted back; if it does not recover, the operation is repeated once; if it still cannot recover, it is handled according to the logic of multiple broken strips. When multiple strips break simultaneously or break frequently in a short period of time, the screw speed of the screw extrusion assembly 212 is reduced to reduce the discharge load, and an audible and visual alarm is triggered while recording all current process parameters. In step S3, the intelligent control system calculates the residual moisture on the surface of the strip using the temperature difference method and dynamically adjusts the dehydration and cooling parameters, including: S31. Temperature Acquisition and Temperature Difference Calculation: The surface temperature field of the material strips is acquired through the temperature detection units at the discharge end of the water tank 320 and the feed end of the pelletizing module 500, respectively. The average surface temperature of each material strip is extracted, and the average temperature of all material strips under the wet condition is calculated. Average temperature of the dried material strips Calculate the temperature difference: ; S32. Calculation of Evaporation Water: Based on the first law of thermodynamics, the sensible heat released by the cooling of the material strip is equal to the latent heat absorbed by the evaporation of water. The evaporation water per unit length of material strip is calculated using the following formula:

[0036] in, The amount of water evaporated per unit length of material bar. The mass per unit length of the strip is calculated from the strip's linear density and the total number of strips. The specific heat capacity at constant pressure of the material strip is predetermined based on the ratio of the matrix resin to the filler. The latent heat of vaporization of water is taken as 2260 kJ / kg.

[0037] S33. Calculation of residual moisture baseline value: based on the initial water film mass of the material strip immediately after it exits the water. Based on the baseline, subtract the evaporation water per unit length of the material strip. To obtain the baseline value of residual moisture. :

[0038] in, The initial water film quality is pre-calibrated based on the type of material and the production process.

[0039] S34. Gray Box Model Compensation and Correction: Construct a shallow neural network gray box compensation model with a structure of 4 nodes in the input layer, 6 nodes in a single hidden layer (with ReLU activation function), and 1 node in the output layer (without activation function); the input feature is temperature difference. The model takes the material strip movement speed v, the ambient relative humidity RH, and the current fan speed ω as inputs, and outputs a compensation coefficient α. The model is trained using a backpropagation algorithm with mean squared error as the loss function and Adam as the optimizer. The compensation coefficient is used to correct the baseline residual moisture value to obtain the actual residual moisture content. : S35, Residual Moisture Closed-Loop Control: This involves controlling the actual residual moisture... Compared with the preset target interval, if If the speed exceeds the target limit, increase the fan component speed; if the fan speed is already at its highest setting and still insufficient, reduce the immersion depth of the material strips; if... If the speed is below the target lower limit, reduce the fan component speed or increase the immersion depth of the material strip.

[0040] S36. Target Interval Dynamic Optimization: Construct a black-box prediction model based on the random forest regression algorithm. Input features include residual moisture. The output includes the material type code, material linear density, material movement speed v, and ambient humidity RH, showing the percentage of defective products. The system iterates through the feasible moisture range and selects... The minimum moisture value is taken as the target center value, and ±15% of the target center value is taken as the allowable fluctuation range. The target control range for residual moisture is dynamically updated. If the predicted minimum proportion of non-conforming products is lower than the preset qualified threshold, no adjustment is made. If it is higher than the threshold, an early warning is triggered.

[0041] In the specific implementation of the above embodiments, the technical features can be combined in any non-contradictory way. For the sake of brevity, not all possible combinations of the above technical features are described. However, as long as the combination of these technical features is not contradictory, it should be considered to be within the scope of this specification.

[0042] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A fully automated plastic production line, characterized in that, It includes an automatic feeding module (100), a mixing and extrusion module (200), a water tank cooling module (300), a water removal module (400), a pelletizing module (500), an intelligent screening module (600), an automatic drying module, and an intelligent control system, arranged sequentially along the material conveying direction. The hybrid extrusion module (200) includes an extruder, which is provided with a hopper (211), a screw extrusion assembly (212) and a discharge port (213) that are interconnected. The automatic feeding module (100) transports the raw materials to the hopper (211). The water tank cooling module (300) includes an initial cooling ramp (310), a water tank (320), an adjustable traction conveying mechanism (330), and a chiller unit; the initial cooling ramp (310) is located below the discharge port (213), the water tank (320) is located below the initial cooling ramp (310), the adjustable traction conveying mechanism (330) is located in the water tank (320), the water tank (320) is provided with a first water inlet and a water outlet, the top of the initial cooling ramp (310) is provided with a second water inlet, and the first water inlet, the water outlet, and the second water inlet are all connected to the chiller unit; The dewatering module (400) includes a conveyor belt (410), a purge pipe (420), and a blower assembly. The feed end of the conveyor belt (410) is located at the end of the water tank (320) away from the mixing extrusion module (200). The blower assembly is connected to the purge pipe (420), and the air outlet of the purge pipe (420) faces the conveyor belt (410). The discharge end of the conveyor belt (410) is connected to the feed end of the pelletizing module (500), the discharge end of the pelletizing module (500) is connected to the feed end of the intelligent screening module (600), and the qualified material discharge end of the intelligent screening module (600) is connected to the feed end of the automatic drying module. The discharge port (213) is equipped with a visual detection unit for collecting images of the material strip status, and the discharge end of the water tank (320) and the feed end of the pelletizing module (500) are respectively equipped with a temperature detection unit for collecting the surface temperature of the material strip. The intelligent control system is connected to the automatic feeding module (100), the mixing extrusion module (200), the water tank cooling module (300), the dewatering module (400), the pelletizing module (500), the intelligent screening module (600), the automatic drying module, the vision detection unit, and the temperature detection unit. The intelligent control system can be used to determine and control the immersion depth, water flow rate, and traction speed of the water tank cooling module (300) and / or the extrusion speed of the mixing extrusion module (200) based on the material strip density and the broken strip information obtained by the vision detection unit. The intelligent control system can also be used to calculate the actual residual moisture on the surface of the material strip based on the material strip surface temperature information obtained by the temperature detection unit, combined with the initial water film mass of the material strip, the material strip density, and the number of material strips obtained by the vision detection unit, and adjust the fan assembly speed of the dewatering module (400) and / or the immersion depth of the water tank cooling module (300) based on the actual residual moisture.

2. The fully automated plastic production line according to claim 1, characterized in that, The adjustable traction conveying mechanism (330) is a tracked conveying mechanism, which includes a track (331), a track drive motor (332), a front end lifting mechanism (333), and a rear end lifting mechanism (334). The track (331) is arranged in the internal cavity of the water tank (320) along the material conveying direction. The track drive motor (332) is fixedly installed on the rear end lifting mechanism (334). The output shaft of the track drive motor (332) is connected to the transmission roller of the track (331). The front end lifting mechanism (333) and the rear end lifting mechanism (334) are both slidably assembled on the side wall of the water tank (320). Alternatively, the adjustable traction conveying mechanism (330) may be a guide wheel type traction mechanism, which includes a bar clamping guide wheel (710), a clamping cylinder (720), a bar traction slider (730), a guide wheel slide rail (740), and a guide wheel slider (750); the bar clamping guide wheel (710) is located below the initial cooling slope (310), the clamping cylinder (720) is connected to the bar clamping guide wheel (710) in a driving connection, and the side wall of the water tank (320) is provided with a traveling slide rail along the length direction. 321), the material traction slider (730) is slidably mounted on the traveling slide rail (321) and connected to the material clamping guide wheel (710); the guide wheel slide rail (740) is disposed in the internal cavity of the water tank (320), including a vertical slide rail section (741) and a horizontal slide rail section (742), the guide wheel slider (750) is slidably mounted on the guide wheel slide rail (740), the horizontal slide rail section (742) can be connected to the vertical slide rail section (741), and is disposed at the bottom of the water tank (320).

3. The fully automated plastic production line according to claim 1, characterized in that, The top of the initial cooling slope (310) is uniformly provided with a plurality of cooling slope water outlet holes (312) along the width direction. A buffer block (313) is provided below the cooling slope water outlet holes (312). The second water inlet is connected to the chiller unit through a branch water pipe equipped with a booster pump and a flow control valve. The branch water pipe is connected to the water outlet of the water tank (320) or to the high-temperature water area of ​​the cooling water tank of the extruder.

4. The fully automated plastic production line according to claim 1, characterized in that, The bottom of the water tank (320) is provided with a bubble manufacturing module (322). The bubble manufacturing module (322) is evenly arranged along the material conveying direction. The bubble manufacturing module (322) is a multi-part split structure, and each split structure is independently connected to the external air passage.

5. The fully automated plastic production line according to claim 1, characterized in that, The mixing extrusion module (200) also includes a waste cleaning component movable to the discharge port (213). The waste cleaning component includes a waste tray (221), a scraper (222), a scraper rotary motor (223), and a scraper cylinder (224). The waste tray (221) is movable to the bottom of the discharge port (213). The scraper (222) is located at the discharge port (213). The output shaft of the scraper rotary motor (223) is connected to the scraper (222). The output end of the scraper cylinder (224) is connected to the scraper rotary motor (223).

6. The fully automated plastic production line according to claim 1, characterized in that, The intelligent screening module (600) includes a vibrating screen (610), a multi-channel color sorter (620), a magnetic sieve, a gravity-type magnetic point amplification module (630), and a discharge pipe (640) connected sequentially along the material conveying direction; the vibrating screen (610) includes an upper screen (611) and a lower screen (612), the aperture of the upper screen (611) is the upper limit of the target particle diameter, and the aperture of the lower screen (612) is the lower limit of the target particle diameter, and the upper screen (611) and the lower screen (612) are detachably connected by an electromagnetic locking structure; the multi-channel color sorter (620) includes a first color sorter. The first color sorting channel (621) and the second color sorting channel (622) are connected. The entrance of the first color sorting channel (621) is located downstream of the vibrating screen (610), and the outlet of the first color sorting channel (621) is connected to the magnetic screening machine. The magnetic screening machine is connected to the gravity magnetic dot amplification module (630). The entrance of the second color sorting channel (622) is located downstream of the gravity magnetic dot amplification module (630), and the outlet of the second color sorting channel (622) is connected to the feeding pipe (640). The gravity magnetic dot amplification module (630) is a vertically arranged non-magnetic pipe, and an electromagnetic heating component is provided on the outer wall of the non-magnetic pipe.

7. The fully automated plastic production line according to claim 1, characterized in that, It also includes an intelligent cleaning module, which comprises a cleaning inlet pipe (800), a cleaning main purging pipe (810), a cleaning secondary purging pipe (820), a cleaning motor (830), and a cleaning heating module (840); the top of the extruder is provided with a mounting base (850), the cleaning motor (830) is fixedly installed on the mounting base (850) and connected to the cleaning main purging pipe (810), and the cleaning motor (830) can drive the cleaning main purging pipe (840). 10) The cleaning machine purging auxiliary pipe (820) rotates in the hopper (211). The cleaning machine air inlet pipe (800) is set on the mounting base (850) and connected to the cleaning machine purging main pipe (810). The cleaning machine purging auxiliary pipe (820) is fixed to the side wall of the cleaning machine purging main pipe (810). The side wall of the cleaning machine purging auxiliary pipe (820) is provided with a purging hole (821). The cleaning machine heating module (840) is covered and set on the outer wall of the hopper (211).

8. The fully automated plastic production line according to any one of claims 1 to 7, characterized in that, The intelligent control system includes a temperature acquisition module, an evaporation water calculation module, a residual moisture benchmark calculation module, and a gray box compensation and correction module. The temperature acquisition module is used to acquire the surface temperature of the material strip collected by the temperature detection unit, obtain the average temperature of the material strip in the wet state and the average temperature of the material strip after air drying, and calculate the temperature difference between the two. The evaporation water calculation module is used to calculate the evaporation water per unit length of material strip based on the principle of thermodynamic heat balance, according to the mass of the material strip per unit length, the specific heat capacity of the material strip at constant pressure, and the temperature difference value. The residual moisture baseline calculation module is used to subtract the amount of water evaporated per unit length of material strip from the initial water film mass when the material strip exits the water source to obtain the residual moisture baseline value. The gray box compensation and correction module is used to output compensation coefficients through a pre-trained shallow neural network gray box compensation model, and to use the compensation coefficients to correct the residual moisture benchmark value to obtain the actual residual moisture on the surface of the material strip.

9. A fully automated plastic production method applied to the fully automated plastic production line according to any one of claims 1 to 8, characterized in that, Includes the following steps: S1. Automatic feeding and melt extrusion: The automatic feeding module (100) quantitatively feeds the raw material into the hopper (211) of the mixing extrusion module (200), and the raw material is extruded into strips from the discharge port (213) after being melted and mixed by the screw extrusion assembly (212). S2, Adaptive cooling conveying: After the material strip is buffered and cooled by the initial cooling slope (310), it enters the water tank (320). The intelligent control system adjusts the position of the adjustable traction conveying mechanism (330) according to the density of the material strip, and controls the immersion depth and water passage path of the material strip. S3, Intelligent Dewatering and Pelletizing: The strip enters the conveyor belt (410) in the dewatering module (400), and the blower assembly provides airflow through the purging pipe (420) to remove the surface water of the strip. The strip after dewatering is sent to the pelletizing module (500) to be cut into pellets. S4. Multi-stage screening and drying: The granules are sequentially screened by the intelligent screening module (600) to select qualified granules, and the qualified granules are sent to the automatic drying module to complete the drying process; S5. Adaptive obstacle removal for broken strips: The vision detection unit monitors the continuity of the strips at the discharge port (213) in real time. When a single broken strip is detected, the intelligent control system increases the water flow rate of the initial cooling slope (310) and increases the traction speed of the adjustable traction conveying mechanism (330). When multiple broken strips are detected, the intelligent control system reduces the screw speed of the screw extrusion assembly (212) and triggers an audible and visual alarm.

10. The fully automated plastic production method according to claim 9, characterized in that, In step S3, the intelligent control system calculates the residual moisture on the surface of the material strip using the temperature difference method and dynamically adjusts the dehydration and cooling parameters, including: S31. Temperature acquisition and temperature difference calculation: Temperature detection units are set at the discharge end of the water tank (320) and the feed end of the pelletizing module (500) to collect the surface temperature of the material strips, obtain the average temperature of all material strips under the wet state and the average temperature of the material strips after air drying, and calculate the temperature difference between the two. S32. Calculate the evaporation water volume: Based on the thermodynamic heat balance principle, the evaporation water volume per unit length of the material strip is calculated according to the mass of the material strip per unit length, the specific heat capacity of the material strip at constant pressure, and the temperature difference value. S33. Calculation of residual moisture baseline value: Based on the initial water film mass when the material strip exits water, subtract the amount of water evaporated per unit length of material strip to obtain the residual moisture baseline value; S34. Gray Box Model Compensation and Correction: Using a pre-trained shallow neural network gray box compensation model, the temperature difference, material strip movement speed, ambient relative humidity, and fan component speed are input, and the compensation coefficient is output; the residual moisture baseline value is corrected using the compensation coefficient to obtain the actual residual moisture. S35. Residual Moisture Closed-Loop Control: The actual residual moisture is compared with a preset target range. If the actual residual moisture is higher than the upper limit of the preset target range, the intelligent control system increases the speed of the fan assembly; if the actual residual moisture is lower than the target lower limit, the intelligent control system decreases the speed of the fan assembly or increases the immersion depth of the material strip. S36. Target Interval Dynamic Optimization: Construct a black-box prediction model based on the random forest algorithm to predict the proportion of defective products under the corresponding working conditions. Perform traversal calculations within the feasible moisture range, select the moisture value corresponding to the minimum proportion of defective products as the target center value, and dynamically update the target range of residual moisture based on the target center value and the allowable fluctuation range.

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