A control method of an automatic feeding device of a high-efficiency plastic color mixer

Abstract

The application provides a control method of an automatic feeding device of a high-efficiency plastic color mixer, relates to the technical field of intelligent equipment, and the device comprises a T-shaped sliding groove lifting storage bin, a crane, a bottom vibration device and a PLC. In the lifting stage, the current / tension double parameters of the crane are collected, the T-shaped block jamming is jointly judged through the peak impact and the periodic fluctuation, the low-frequency large-amplitude asymmetric impact unjamming vibration is started, the stiffness index is adaptively matched according to the jamming waveform to construct the vibration parameters, the inner ring phase closed loop and the outer ring step enhancement layered adjustment are set, the return pulse tension is synchronously applied to assist in loosening the jamming, and the fluctuation threshold is avoided to avoid the vibration self-interference. After the bin reaches the unloading position, the discharge pipe is rotated, the discharge signal is wave-trapped and filtered to eliminate the vibration noise, the effective discharge pulse is identified to judge the discharging state, and the two types of vibration modes of unjamming and discharging are isolated through interlocking. The application solves the problems of the lifting sliding block jamming and the discharging sensor misjudgment, and improves the feeding stability and the plastic material discharging smoothness.

Description

Technical Field

[0001] This invention belongs to the field of intelligent equipment technology, specifically relating to a control method for an automatic feeding device for a high-efficiency plastic color mixing machine. Background Technology

[0002] In the automatic feeding device of a plastic mixing machine equipped with a T-shaped chute and a T-shaped block lifting and guiding mechanism, the storage bin is vertically raised and lowered along the chute under the drive of a crane. In actual use, plastic particles or dust can easily enter the mating gap between the T-shaped chute and the T-shaped block. Coupled with uneven load on the bin body or thermal deformation of the structure, the T-shaped block may become stuck in the chute. Once stuck, the load on the crane increases sharply. If it continues to be forcibly pulled up, it may burn out the crane motor, damage the chute guide rail, or break the lifting steel cable.

[0003] Current methods typically rely on manual monitoring: operators manually stop the machine after hearing abnormal noises or observing vibrations in the hopper, then attempt to clear the jam by tapping the hopper or repeatedly jogging the crane. This method is slow to respond, unable to automatically identify and handle the jam the instant it occurs, and the manual handling is arbitrary, easily causing secondary damage to the equipment. Therefore, there is an urgent need for a control method that can automatically identify T-block jamming and immediately activate the actuator to release the jam. Summary of the Invention

[0004] In view of the above-mentioned defects or deficiencies in the prior art, a control method for an automatic feeding device of a high-efficiency plastic color mixing machine is provided, which is applied to the automatic feeding device; the automatic feeding device includes: A color mixing machine with an opening at the top; The first fixed plate is vertically fixed to the side wall of the color mixing machine, and a T-shaped groove extending in the vertical direction is provided on it; The storage bin is slidably fitted into the T-shaped groove by a T-shaped block. The bottom of the storage bin is inclined and a discharge hole is opened at the lower end. A rotatable discharge pipe is connected to the discharge hole. A crane is fixed to the upper part of the first fixed plate and connected to the storage silo via lifting steel cables; A vibration device is installed at the bottom of the storage bin to apply vibration to the storage bin; The PLC controller is electrically connected to both the crane and the vibration device. The control method is executed by the PLC controller and includes the following steps: The crane is controlled to drive the storage bin to move up and down along the T-shaped chute, and monitoring parameters reflecting the load of the crane are acquired in real time during this process; When the monitored parameters meet the preset jamming judgment conditions, the crane is controlled to pause or decelerate, and the vibration device is activated to work in the preset unblocking mode; after the unblocking is completed, the crane is controlled to resume operation. When the storage bin is detected to have reached the preset unloading position, the discharge pipe is controlled to rotate to the unloading posture, and the discharge detection signal reflecting the material outflow status is acquired in real time. When the discharge detection signal indicates that the material flow is not smooth, the vibration device is activated to assist the unloading mode; when the material resumes continuous flow or the preset conditions are met, the vibration device is stopped.

[0005] According to the technical solution provided in this application, the monitoring parameters reflecting the load of the crane include the driving current of the crane and / or the real-time tension value of the driving wire rope; The preset jamming determination conditions include at least one of the following: First determination condition: The real-time sampled value of the monitoring parameter shows a shock wave peak with an upward slope exceeding a preset slope threshold within the first preset short window, and the peak value of the shock wave peak exceeds a certain multiple of the preset dynamic reference value. Second determination condition: After the real-time sampled value of the monitoring parameter is processed by high-pass filtering, the AC component fluctuation amplitude obtained within the second preset time window exceeds the preset fluctuation threshold multiple times consecutively. If the monitoring parameters simultaneously meet the first and second determination conditions, it is determined that the T-shaped block is momentarily stuck in the T-shaped groove and tends to become continuously stuck.

[0006] According to the technical solution provided in this application, the card unlocking mode includes: The vibration device is controlled to operate with a preset combination of unlocking parameters; the combination of unlocking parameters includes: a vibration frequency range of 15Hz to 35Hz in the low frequency range, a vibration amplitude of 70% to 100% of the maximum amplitude of the vibration device, and a vibration waveform of an asymmetric waveform with intermittent impact characteristics. When the vibration device operates with the aforementioned unblocking parameter combination, the generated vibration force is transmitted through the bottom plate of the storage bin to the mating gap between the T-shaped block and the T-shaped groove, causing the T-shaped block to produce low-frequency large-amplitude vibrations parallel to the extension direction of the groove, thereby eliminating local stress concentrations or instantaneous foreign object embedding that cause jamming.

[0007] According to the technical solution provided in this application, during the unlocking process, the driving current of the crane and / or the real-time tension value of the driving wire rope are continuously acquired, and the following unlocking exit logic is executed: At the same moment the card-unlocking vibration is initiated, the fluctuation threshold in the second judgment condition is automatically increased by a preset ratio to offset the periodic fluctuation interference introduced by the vibration device itself on the monitoring parameters. If, within the preset unblocking evaluation window, the monitoring parameters no longer simultaneously meet the first judgment condition and the second judgment condition after floating, the unblocking is determined to be successful. The vibration device is controlled to stop, and the crane is controlled to continue lifting at a preset recovery speed lower than the operating speed before the blockage. During the recovery lifting process, the monitoring parameters are continuously acquired. If the monitoring parameters again simultaneously meet the first judgment condition and the second judgment condition after floating, a secondary blockage is determined to have occurred. The crane is immediately paused and re-enters the unblocking mode. If, within the card-unlocking evaluation window, the monitoring parameters still simultaneously meet the first judgment condition and the second judgment condition after floating, then the single card-unlocking attempt is determined to be unsuccessful. The vibration device is then controlled to gradually increase the vibration frequency and / or amplitude by a preset increment step and then the card-unlocking vibration is performed again until the preset maximum card-unlocking strength limit is reached or the card-unlocking is successful. If, after reaching the maximum unlocking strength limit, the monitoring parameters still simultaneously meet the first judgment condition and the second judgment condition after floating, then the unlocking is determined to have failed, the crane is controlled to stop running, and a first type of fault alarm signal is output.

[0008] According to the technical solution provided in this application, during the card unlocking process: The single card-unlocking vibration within the card-unlocking evaluation window constitutes the inner ring adjustment layer, and the vibration frequency and / or amplitude are gradually increased according to the preset increase step size to constitute the outer ring adjustment layer; the inner ring adjustment layer is effective in real time during a single card-unlocking vibration, and the outer ring adjustment layer is only triggered to update after the card-unlocking evaluation window of the previous card-unlocking vibration ends, and the two do not act on the same vibration cycle at the same time. During the single card release vibration, the crane is controlled to apply a periodic pulsating auxiliary lifting force to the storage bin in sync with the vibration excitation signal of the vibration device. The amplitude of the pulsating auxiliary lifting force does not exceed 10% of the rated lifting force of the crane, and the lifting force pulse is applied during the return phase of the vibration device in each vibration cycle.

[0009] According to the technical solution provided in this application, during a single card unlocking vibration, the PLC controller also performs the following closed-loop optimization steps: The AC component of the crane drive current is continuously collected, and the phase lag angle of the AC component of the drive current relative to the vibration excitation signal of the vibration device is calculated in real time. Closed-loop adjustment is performed using the phase lag angle as feedback: when the phase lag angle is greater than the preset jamming threshold, it indicates that the jamming has not loosened. The vibration device is controlled to continuously reduce the vibration frequency and simultaneously increase the vibration amplitude by a preset step size until the phase lag angle is reduced to below the jamming threshold. When the phase lag angle decreases to below the jamming threshold, it is determined that the jamming has loosened, the parameter adjustment is stopped, and the current vibration parameters are used to continue running for a preset consolidation time before exiting the current unblocking vibration. The closed-loop adjustment has a safety boundary: when the vibration frequency decreases to the preset minimum allowable frequency or the vibration amplitude increases to the maximum allowable amplitude of the vibration device, the parameter adjustment is stopped and the current parameters are maintained until the current card unlocking vibration ends.

[0010] According to the technical solution provided in this application, the control method further includes: prohibiting the activation of the auxiliary unloading mode while the storage bin has not reached the preset unloading position; and prohibiting the crane from performing lifting and lowering actions during the operation of the auxiliary unloading mode.

[0011] According to the technical solution provided in this application, the real-time acquisition of the discharge detection signal reflecting the material outflow status includes the following steps: The initial discharge detection signal is acquired by the first sensor installed at the outlet end of the discharge pipe according to a preset sampling period; at the same time, the frequency and phase information of the current vibration excitation signal of the vibration device are acquired in real time. Using the frequency of the vibration excitation signal as a reference, the initial discharge detection signal is subjected to adaptive notch filtering to filter out periodic interference components with the same frequency as the vibration excitation signal, thereby obtaining an intermediate signal after vibration decoupling. The intermediate signal is compared with the AC component of the driving current of the crane in the auxiliary unloading mode in the time domain: only when the intermediate signal shows pulse characteristics and the AC component of the driving current does not show impact fluctuation characteristics related to the collapse of the material bridging at the corresponding time, the current pulse of the intermediate signal is determined to be a valid discharge pulse. The cumulative number of effective discharge pulses, pulse interval, or duty cycle are used as the discharge detection signal reflecting the material outflow status.

[0012] According to the technical solution provided in this application, the vibration frequency, vibration amplitude, and intermittent impact duty cycle of the asymmetric waveform in the card unlocking parameter combination are determined by the PLC controller according to the following steps when the card unlocking mode is started: The peak value and peak rise time of the shock wave of the monitoring parameters are traced back one preset feature extraction window from the instant the trigger jamming judgment condition is extracted. The peak value of the shock wave is compared with multiple preset peak classification thresholds to generate a peak level that reflects the magnitude of the jamming resistance; the rise time of the shock wave peak is compared with multiple preset time classification thresholds to generate a time level that reflects the suddenness of the jamming. The peak level is given as the first priority and the time level as the second priority. The two are combined into a comprehensive jamming stiffness index, which monotonically increases as the peak level and time level increase.

[0013] According to the technical solution provided in this application, the vibration frequency, vibration amplitude, and intermittent impact duty cycle in the de-jamming parameter combination are determined according to the comprehensive jamming stiffness index according to the following rules: The larger the comprehensive sticking stiffness index, the closer the vibration frequency value is to the lower limit of the preset frequency range of the unlocking mode, the closer the vibration amplitude value is to the maximum amplitude of the vibration device, and the closer the intermittent impact duty cycle value is to zero. The smaller the comprehensive sticking stiffness index, the closer the vibration frequency value is to the upper limit of the preset frequency range of the unlocking mode, the closer the vibration amplitude value is to 70% of the maximum amplitude, and the closer the intermittent impact duty cycle value is to the preset maximum duty cycle limit. The lower and upper limits of the frequency range, as well as 70% of the maximum amplitude and the maximum duty cycle limit, are all within the range of the card unlocking parameter combination.

[0014] Compared with the prior art, the beneficial effects of this application are as follows: I. Instant Automatic Jamming Recognition to Prevent Equipment Damage. By acquiring real-time monitoring parameters of the crane load during lifting and comparing them with preset jamming judgment conditions, the system can automatically identify the anomaly the moment the T-block jams, without manual observation or intervention. Upon identification, the system immediately controls the crane to pause or decelerate, fundamentally avoiding equipment damage such as motor overload, chute deformation, or cable breakage caused by forced lifting.

[0015] II. Automatic Disengagement of Jams, Enhancing Operational Continuity. Upon detecting jamming, the system automatically activates a vibration device to operate in disengagement mode, using vibration to eliminate localized stress concentrations or foreign object embedding between the T-block and the T-groove. After successful disengagement, lifting and lowering automatically resume. The entire process requires no machine downtime for manual intervention, significantly improving the efficiency and operational continuity of the automatic feeding device.

[0016] 3. The same vibration device is reused for both lifting / unblocking and unloading assistance, resulting in a compact structure. The control method distinguishes between the unblocking mode and the auxiliary unloading mode in terms of timing: the unblocking mode is triggered only when there is jamming during the lifting phase, while the auxiliary unloading mode is triggered only when material flow is obstructed during the unloading phase. The two modes reuse the same vibration device in a time-sharing manner without adding extra hardware, achieving a leap in control functionality based on the existing mechanical structure. Attached Figure Description

[0017] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 A flowchart illustrating the steps of the control method for the automatic feeding device of the high-efficiency plastic color mixing machine provided in this application; Figure 2 This is a schematic diagram of the automatic feeding device for the high-efficiency plastic color mixing machine provided in this application. Figure 3 This is an exploded structural diagram of the automatic feeding device for a high-efficiency plastic color mixing machine. Figure 4 for Figure 3 Enlarged view of point A in the middle. Figure 5 This is a schematic diagram of the storage silo structure. Figure 6 This is a schematic diagram of the support block structure. The following are the labels in the diagram: 1. Color mixer; 2. First fixed plate; 3. Storage bin; 4. T-shaped chute; 5. T-shaped block; 6. Rubber pad; 7. Support plate; 8. Crane; 9. Second fixed plate; 10. Discharge hole; 11. Discharge pipe; 12. Third fixed plate; 13. Limiting groove; 14. Limiting ring; 15. Reinforcing plate; 16. Protective cover; 17. Rotating plate; 18. Drive motor; 19. Fixed groove; 20. Support block. Detailed Implementation

[0018] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0019] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] Example 1 As mentioned in the background section, this application proposes a control method for an automatic feeding device of a high-efficiency plastic color mixing machine, applied to the automatic feeding device; the automatic feeding device includes: Color mixing machine 1, which has an opening at the top; The first fixed plate 2 is vertically fixed to the side wall of the color mixing machine 1, and a T-shaped groove 4 extending in the vertical direction is provided on it; The storage bin 3 is slidably fitted into the T-shaped groove 4 by the T-shaped block 5. The bottom of the storage bin 3 is inclined and a discharge hole is opened at the lower end. A rotatable discharge pipe is connected to the discharge hole. A crane is fixed to the upper part of the first fixed plate 2 and connected to the storage bin 3 via a lifting steel cable; A vibration device is installed at the bottom of the storage bin 3 to apply vibration to the storage bin 3; The PLC controller is electrically connected to both the crane and the vibration device. Specifically, refer to Figures 2 to 6 The automatic feeding device includes a color mixer 1, which has an open top and a movably fitted sealing cover. A first fixing plate 2 is fixedly installed on the outer wall of the color mixer 1, and a T-shaped groove 4 extending vertically is formed on the side wall of the first fixing plate 2 away from the color mixer 1. The storage bin 3 is a hollow container structure with an open top. Two T-shaped blocks 5 are provided on the side wall of the storage bin 3 near the first fixing plate 2. Both T-shaped blocks 5 are slidably engaged in the T-shaped groove 4, forming a guide pair for the vertical movement of the storage bin 3 along the first fixing plate 2.

[0021] A support plate 7 is fixedly installed on the upper side wall of the first fixed plate 2 away from the color mixer 1, and a crane 8 is fixedly installed on the top surface of the support plate 7. A second fixed plate 9 is fixedly installed on the top surface of the storage hopper 3, and a lifting cable is wound on the crane 8, with the end of the lifting cable away from the crane 8 fixedly connected to the second fixed plate 9. A reinforcing plate 15 is also provided on the side wall of the first fixed plate 2 away from the color mixer 1, and the reinforcing plate 15 is fixedly connected to the bottom surface of the support plate 7 to enhance the load-bearing capacity of the support plate 7.

[0022] The bottom sidewall of the storage bin 3 is inclined, with its left end being lower than its right end. A discharge hole 10 is provided at the lower end of the left side wall of the storage bin 3, and a discharge pipe 11 is rotatably sleeved on the inner wall of the discharge hole 10. A limiting groove 13 is provided on the inner wall of the discharge hole 10, and a limiting ring 14 is fixedly sleeved on the outer wall of one end of the discharge pipe 11. The limiting ring 14 is rotatably disposed in the limiting groove 13, so that the discharge pipe 11 can rotate freely within the discharge hole 10 without falling off.

[0023] A support block 20 is fixedly installed on the bottom surface of the storage bin 3. A fixing groove 19 is opened on one side wall of the support block 20, and a drive motor 18 is installed in the fixing groove 19. The drive motor 18 has a drive end, and the drive end is connected to a rotating plate 17. The rotating plate 17 is not centrally located on the drive end, that is, there is an eccentricity between the center of mass of the rotating plate 17 and the rotation axis of the drive motor. When the drive motor 18 rotates, the rotating plate 17 generates a periodic centrifugal force, which in turn applies mechanical vibration to the storage bin 3. The drive motor 18 and the rotating plate 17 together constitute a vibration device. A protective cover 16 is also provided on one side wall of the support block 20. The protective cover 16 has a hollow interior and an open end, which covers the rotating plate 17 inside to prevent the rotating parts from accidentally injuring the operator.

[0024] A third fixed plate 12 is fixedly installed on the bottom surface of the first fixed plate 2, and a rubber pad 6 is fixedly installed on the bottom surface of the support block 20. When the storage bin 3 descends to the initial position, the rubber pad 6 contacts the third fixed plate 12, which plays a role in buffering and shock absorption.

[0025] A PLC controller is also fixedly installed on the outer wall of the color mixing machine 1. The PLC controller is electrically connected to the crane 8 and the drive motor 18 respectively.

[0026] The following sensors and detection devices are also added to the device on which the control method of this application is based: A current sensor is connected in series in the power supply circuit of crane 8 to collect the drive current signal of crane 8 in real time and output it to the analog input port of PLC controller. As an alternative or supplementary solution, a tension sensor can be connected in series at the connection between the lifting cable and the second fixing plate 9 to obtain the real-time tension value of the wire rope. The current sensor and / or tension sensor provide the PLC controller with monitoring parameters reflecting the crane load.

[0027] A first sensor is installed at the outlet end of the discharge pipe 11. The first sensor is a through-beam photoelectric sensor or a microwave material flow switch, which is used to detect whether material flows out of the discharge pipe 11 and outputs a discharge detection signal indicating the material flow status to the PLC controller.

[0028] A first proximity switch or limit switch is installed at a preset unloading position on the upper part of the first fixed plate 2 to detect whether the storage bin 3 has reached the unloading position. When the storage bin 3 rises to the unloading position, the switch is triggered, and the PLC controller confirms that the storage bin is in place.

[0029] A second proximity switch or limit switch is installed at the initial position below the first fixed plate 2 to detect whether the storage bin 3 has fallen back to the initial position.

[0030] Example 2 Based on Example 1, this example proposes a control method for an automatic feeding device of a high-efficiency plastic color mixing machine, which is executed by the PLC controller, such as... Figure 1 As shown, it includes the following steps: S1. Control the crane to drive the storage bin to rise and fall along the T-shaped chute, and acquire monitoring parameters reflecting the load of the crane in real time during this process; S2. When the monitoring parameters meet the preset jamming judgment conditions, control the crane to pause or decelerate, and start the vibration device to work in the preset unblocking mode; after the unblocking is completed, control the crane to resume operation. S3. When the storage bin is detected to have reached the preset unloading position, the discharge pipe is controlled to rotate to the unloading posture, and the discharge detection signal reflecting the material outflow status is acquired in real time. S4. When the discharge detection signal indicates that the material flow is not smooth, the vibration device is activated to assist the unloading mode; when the material resumes continuous flow or the preset conditions are met, the vibration device is stopped.

[0031] Specifically, this method is executed by a PLC controller. Based on the existing mechanical structure, it uses software logic to achieve self-identification and automatic unblocking of jams during the lifting process, as well as self-sensing of the discharge status and automatic assisted unloading during the unloading process. The following describes the specific implementation process of each step of this method in detail with reference to the hardware configuration described in Example 1.

[0032] During the lifting control phase, the PLC controller first controls the contactor or frequency converter of the crane 8 through the digital output module, energizing the motor of the crane 8 in the forward direction. This drives the reduction mechanism to rotate the drum, winding the lifting cable and applying a vertical upward lifting force to the storage bin 3. Under this lifting force, the two T-shaped blocks 5 fixed to the side wall of the storage bin 3 slide upward along the T-shaped groove 4 of the first fixed plate 2. Throughout the lifting process, the PLC controller acquires monitoring parameters reflecting the load of the crane 8 in real time at a fixed sampling period. The sampling period setting needs to balance response timeliness and signal stability. In this embodiment, a period value of ten to twenty milliseconds is selected. This period value is much smaller than the time constant of the T-shaped block 5 during the jamming process in the T-shaped groove 4, which can completely capture the transient signal characteristics when jamming occurs. The specific method for acquiring the monitoring parameters is as follows: The current sensor converts the AC current of any one phase of the three-phase power supply line of the crane 8 motor into a corresponding DC voltage signal. This voltage signal is input to the analog input module of the PLC controller, where it is converted into a digital signal by the built-in analog-to-digital converter. The effective value of the drive current is then obtained through root mean square (RMS) calculation or peak detection. If a tension sensor is configured, the strain gauge bridge inside the sensor generates a weak voltage proportional to the tension of the lifting cable under the tension. After amplification and conditioning, this voltage is also input to the analog input module. The PLC controller reads this value as the real-time tension value of the lifting cable. Both of these parameters directly reflect the load changes of the crane 8 and can be used individually or simultaneously and then weighted to improve the robustness of jamming detection.

[0033] In each sampling cycle, the PLC controller sends the acquired monitoring parameters to a preset jamming judgment logic for comparison. When the judgment condition is met, the PLC controller immediately executes two protective actions: First, it reduces the operating frequency of the crane 8 motor through the frequency converter, or cuts off the enable signal of the crane 8 motor to put it into a free stop state, thereby limiting the increase of the lifting cable tension and avoiding cable breakage or motor stall and burnout; Second, it outputs a start command and a preset speed reference value to the motor driver connected to the drive motor 18, causing the drive motor 18 to drive the rotating plate 17 to rotate, and the vibration device enters the unblocking mode. The selection of vibration parameters, the transmission path of vibration force, and the unblocking mechanism of vibration in the unblocking mode will be described in detail in the embodiments of claim 3. During the operation of the unblocking mode, the PLC controller continuously uses the monitoring parameters of the crane 8 load to evaluate the unblocking effect. Once the jamming is determined to be eliminated, the vibration device is stopped, and a control command to resume operation is output to the crane 8, so that the storage bin 3 continues to move up and down along the T-shaped chute 4.

[0034] When the PLC controller receives a trigger signal indicating that the storage bin 3 has reached the unloading position via a detection switch installed on the upper part of the first fixed plate 2 at the preset unloading position, it determines that the storage bin 3 has reached the unloading position. At this time, the PLC controller outputs prompt information through the human-machine interface, guiding the operator to manually rotate the rotatable discharge pipe 11 from the storage position to the unloading position, so that the outlet end of the discharge pipe 11 overlaps the edge of the top opening of the color mixer 1. The discharge pipe 11 rotates within the limiting groove 13 on the inner wall of the discharge hole 10 through the limiting ring 14, and will not fall off during the rotation. During the unloading process, the PLC controller acquires the discharge detection signal reflecting the material flow status in real time. This signal comes from the first sensor installed at the outlet end of the discharge pipe 11. When the first sensor is a through-beam photoelectric sensor, its transmitting end and receiving end are respectively installed on both sides of the cross-section of the outlet of the discharge pipe 11. When plastic particles pass through the middle, the light is blocked, and the output level of the receiving end changes. The PLC controller captures this changing edge through the high-speed counting module or the interrupt input port, forming a material passing pulse sequence. When the first sensor is a microwave material flow switch, it emits microwaves into the discharge pipe 11 and receives reflected waves. The change in dielectric constant caused by the material passing through changes the amplitude or phase of the reflected wave. The internal circuit of the sensor converts this change into a switching signal output, and the PLC controller acquires the signal in the same way.

[0035] The PLC controller performs real-time statistical analysis on the collected materials using pulse sequences. Specifically, it accumulates the number of pulses within a preset sliding time window. If this number is lower than a preset lower limit, or the interval between two adjacent pulses exceeds a preset maximum allowable interval, it is determined that the material flow is obstructed. This determination effectively identifies reduced material flowability in the discharge port 10 area caused by material bridging, arching, or adhesion to the walls inside the storage bin 3. Once obstructed material flow is determined, the PLC controller immediately activates the vibration device to assist in the unloading mode. The vibration parameters of the auxiliary unloading mode differ from those of the unblocking mode; its vibration frequency is typically higher than that of the unblocking mode, while its amplitude is lower, to avoid excessive material splashing from the discharge pipe 11 or excessive shaking of the discharge pipe 11 during unloading. After the vibration device is activated, the vibration force generated by the eccentric rotation of the rotating plate 17 is transmitted to the bottom plate of the storage bin 3 through the support block 20. The bottom plate is continuously subjected to periodic vibration, disrupting the interlocking structure between material particles within the storage bin 3, gradually collapsing the bridging area, and restoring material flowability. When the PLC controller detects that the material pulse sequence has resumed continuity, or the cumulative running time of the auxiliary unloading mode has reached the preset maximum auxiliary time protection value, it controls the drive motor 18 to stop rotating, the vibration device to stop, and the unloading assistance to end.

[0036] The technical advantages of this solution are as follows: it transforms the experience-based operation of manually judging jams and manually tapping to unblock them into a self-sensing and self-processing closed loop based on real-time load signals, improving the response speed from seconds to milliseconds; simultaneously, it transforms the manual observation of material flow and manual start / stop of vibration assistance during the unloading process into automatic judgment and execution based on discharge detection signals, avoiding frequent manual intervention. Its technical principle is as follows: it utilizes the physical coupling relationship between the electrical parameters of the crane 8 and the mechanical load of the T-block 5 within the T-shaped chute 4 as an indirect sensing means of the lifting state; it utilizes the photoelectric or microwave signal at the port of the discharge pipe 11 as a direct sensing means of the unloading state; and the PLC controller acts as a unified decision-making center, performing time-division multiplexing of the two sets of sensing signals with the same vibration actuator composed of the drive motor 18 and the rotating plate 17 under time-sequence isolation conditions, thereby enabling a single controller to control a single vibration device to complete auxiliary tasks under two different working conditions.

[0037] In a preferred embodiment, the monitoring parameters reflecting the load of the crane include the driving current of the crane and / or the real-time tension value of the driving wire rope; The preset jamming determination conditions include at least one of the following: First determination condition: The real-time sampled value of the monitoring parameter shows a shock wave peak with an upward slope exceeding a preset slope threshold within the first preset short window, and the peak value of the shock wave peak exceeds a certain multiple of the preset dynamic reference value. Second determination condition: After the real-time sampled value of the monitoring parameter is processed by high-pass filtering, the AC component fluctuation amplitude obtained within the second preset time window exceeds the preset fluctuation threshold multiple times consecutively. If the monitoring parameters simultaneously meet the first and second determination conditions, it is determined that the T-shaped block is momentarily stuck in the T-shaped groove and tends to become continuously stuck.

[0038] Specifically, the monitoring parameters are selected from at least one of the drive current of the crane 8 and the real-time tension value of the lifting cable. When the drive current is selected, the output of the current sensor connected in series in the power supply circuit of the crane 8 enters the PLC controller through the analog input module, and updates the effective current value once in each scanning cycle. The PLC controller maintains a circular buffer with a length of several hundred milliseconds in memory, storing the current sampling values ​​of the most recent cycles in chronological order. When the lifting cable tension value is selected, the signal of the tension sensor installed at the connection between the lifting cable and the second fixed plate 9 is collected and stored through the same path. The preset jamming judgment conditions include a first judgment condition and a second judgment condition. The two conditions characterize the jamming of the T-block 5 in the T-shaped groove 4 from two dimensions: time-domain impact characteristics and frequency-domain fluctuation characteristics, respectively. The PLC controller calculates the satisfaction of the two conditions simultaneously in each sampling cycle.

[0039] The specific calculation process for the first judgment condition is as follows: The PLC controller defines a sliding short-time window with a width of tens of milliseconds, containing several sampling points. In each sampling period, the difference between the sampled value at the end of the window and the sampled value at the beginning of the window is calculated, and then divided by the window time length to obtain the average rising slope within the window. If the rising slope exceeds a preset slope threshold, it is further checked whether the maximum value of the sampled value within the window constitutes a shock wave peak. The shock wave peak identification method is as follows: the maximum value within the window must be greater than the average value of all sampled values ​​in the two short-time windows before and after the window multiplied by a preset peak discrimination coefficient, thereby eliminating false peaks. When a shock wave peak is confirmed to have appeared, the peak value of the peak is compared with a preset dynamic reference value. The dynamic reference value is a reference level calculated in real time by the PLC controller based on the current load status of the storage bin 3. The calculation method is as follows: First-order low-pass filtering is applied to the monitored parameters. The difference equation for the low-pass filter is that the current filtered value equals the previous filtered value plus the filter coefficient multiplied by the difference between the current sampled value and the previous filtered value. A smaller filter coefficient results in a larger time constant for the low-pass filter, which can smooth out brief impacts while tracking normal load changes. The dynamic reference value is obtained by multiplying the filtered output value by a coefficient related to the current lifting speed. If the peak value of the impact wave exceeds a certain multiple of this dynamic reference value, the first judgment condition is met. This multiple is usually set between 1.3 and 2.0, and the specific value is determined on-site based on the fit clearance between the T-shaped chute 4 and the T-shaped block 5, the weight of the storage bin 3, and the power of the crane 8.

[0040] The specific calculation process for the second judgment condition is as follows: The PLC controller performs digital high-pass filtering on the sampled sequence of monitoring parameters, filtering out DC components and slowly changing trend terms, retaining only the AC components reflecting rapid fluctuations. The high-pass filter is implemented using a first-order infinite impulse response digital filter. Its difference equation is that the current output value equals coefficient a multiplied by the output value of the previous cycle plus coefficient a multiplied by the difference between the current input value and the input value of the previous cycle. Coefficient a is determined by the cutoff frequency and the sampling period. The cutoff frequency is set in the range of several hertz to tens of hertz, which covers the low-to-mid-frequency mechanical vibrations caused by the sliding-viscous effect of T-block 5 in a stuck state. After taking the absolute value of the high-pass filter output, it is compared with the preset fluctuation threshold. The principle for setting the fluctuation threshold is: when the storage bin 3 is rising and falling normally and smoothly, the statistical average of the absolute value of the high-pass filter output is multiplied by a margin coefficient to ensure that fluctuations will not trigger the condition under normal operating conditions. The PLC controller counts the number of times the absolute value of the high-pass filter output continuously exceeds a fluctuation threshold within a wider sliding window. The window width is typically from hundreds of milliseconds to several seconds to cover at least several sliding-sticky cycles. If the number of consecutive exceedances reaches a preset counting threshold, the second judgment condition is met.

[0041] The PLC controller performs a logical AND operation on two conditions: only when both conditions are met simultaneously is it determined that the T-block 5 is momentarily stuck in the T-groove 4 and tends to become permanently stuck. The physical meaning of this combined criterion is as follows: the first condition captures the instantaneous impact event of the T-block 5 getting stuck in the T-groove 4. This impact event corresponds to the instantaneous conversion of the crane 8's rotational kinetic energy into an impact force on the lifting cable when the T-block 5 abruptly changes from a sliding state to a stuck state; the second condition confirms that this impact event is not isolated and occasional, but is accompanied by continuous sliding-viscous friction between the T-block 5 and the inner wall of the T-groove 4. Both conditions must occur together to constitute a truly harmful, continuous jamming. At the output of the logical AND operation, the PLC controller also adds a short-duration anti-jitter confirmation step, requiring the combined conditions to remain true for more than one confirmation cycle to avoid false triggering caused by signal glitches.

[0042] In a preferred embodiment, the card unlocking mode includes: The vibration device is controlled to operate with a preset combination of unlocking parameters; the combination of unlocking parameters includes: a vibration frequency range of 15Hz to 35Hz in the low frequency range, a vibration amplitude of 70% to 100% of the maximum amplitude of the vibration device, and a vibration waveform of an asymmetric waveform with intermittent impact characteristics. When the vibration device operates with the aforementioned unblocking parameter combination, the generated vibration force is transmitted through the bottom plate of the storage bin to the mating gap between the T-shaped block and the T-shaped groove, causing the T-shaped block to produce low-frequency large-amplitude vibrations parallel to the extension direction of the groove, thereby eliminating local stress concentrations or instantaneous foreign object embedding that cause jamming.

[0043] Specifically, the card unlocking mode is achieved by the PLC controller controlling the operating parameters of the drive motor 18. The drive motor 18 is an AC asynchronous motor or a DC brushless motor, and the matching motor driver receives analog voltage signals or high-speed pulse sequences output by the PLC controller as speed commands. After determining that the card unlocking mode has been entered, the PLC controller outputs a set of specific control parameters to the motor driver, causing the rotating plate 17 to rotate according to the specified vibration frequency, vibration amplitude, and vibration waveform. The vibration frequency is controlled by changing the speed of the drive motor 18. The PLC controller calculates the corresponding target motor speed based on the preset vibration frequency value. This calculation relationship is determined by the number of pole pairs of the drive motor 18 and the mechanical transmission ratio between the rotating plate 17 and the motor output shaft. If the drive motor 18 and the rotating plate 17 are coaxially and directly connected, the motor's revolutions per second equals the vibration frequency. The PLC controller outputs an analog voltage proportional to the target speed to the motor driver through the digital-to-analog converter module, or sends high-speed pulses with a frequency corresponding to the target speed through the transistor output unit. After receiving the command, the motor driver adjusts the voltage or current at the motor terminals to stabilize the drive motor 18 at the target speed. The initial value of the vibration frequency is determined when the card unlocking mode is started. The specific determination method is as follows: the PLC controller extracts the peak value and rise time of the shock wave of the monitoring parameters within a preset feature extraction window at the instant the triggering jam judgment condition is triggered. The peak value and rise time are compared with multiple preset graded thresholds to generate peak value and time value. The peak value is given the first priority and the time value is given the second priority to obtain the comprehensive jam stiffness index. The larger the comprehensive jam stiffness index, the closer the vibration frequency value is to the lower limit of 15Hz. The smaller the comprehensive jam stiffness index, the closer the vibration frequency value is to the upper limit of 35Hz.

[0044] The vibration amplitude control is related to the eccentricity and rotational speed of the rotating plate 17. In the mechanical structure of this device, the eccentricity of the rotating plate 17 is a fixed value, determined by its non-centered mounting position on the drive end. Therefore, the vibration amplitude is proportional to the square of the rotational speed of the rotating plate 17. When the PLC controller needs to increase the amplitude, it outputs a higher target rotational speed command to the motor driver; when it needs to decrease the amplitude, it outputs a lower target rotational speed command. Simultaneously, to prevent the amplitude from exceeding the safety limit of the vibration device's maximum amplitude, the PLC controller internally sets a rotational speed limit. When the target rotational speed exceeds this limit, it automatically clamps to the limit. The maximum amplitude corresponding to this limit is 100% of the vibration device's maximum amplitude. The amplitude range in the de-card parameter combination is limited to between 70% and 100% of the maximum amplitude. Therefore, when calculating the target rotational speed, the PLC controller converts the ratio of the required amplitude to the maximum amplitude into a corresponding rotational speed percentage, and then maps this percentage to a specific target rotational speed value for output.

[0045] The asymmetric and intermittent impact characteristics of the vibration waveform are achieved through the periodic adjustment of the drive motor 18 speed by the PLC controller. Within one vibration cycle, the PLC controller sets the target motor speed as a time-varying curve, which is divided into three stages: the impact segment, the return segment, and the intermittent segment. The impact segment is short in duration, and the target speed is set to a higher value, causing the rotating plate 17 to accelerate during this stage, generating a large centrifugal force peak and applying a high-amplitude, short-duration impact force to the bottom plate of the storage hopper 3. The return segment is longer in duration, and the target speed is set to a lower value, causing the rotating plate 17 to decelerate, generating a smaller centrifugal force, providing space for the T-shaped block 5 to rebound and release stress. During the intermittent segment, the PLC controller outputs a zero-speed command or an enable / disable signal to the motor driver, causing the drive motor 18 to stop briefly. The rotating plate 17 slides due to inertia or comes to a complete stop, forming a clear force interval between two adjacent impacts. The intermittent impact duty cycle is defined as the ratio of the impact segment duration to the entire vibration cycle duration. The smaller this ratio, the shorter the interval between two adjacent impacts and the greater the impact density. The initial value of the intermittent impact duty cycle is determined by the comprehensive jamming stiffness index. A larger comprehensive jamming stiffness index results in a duty cycle value closer to zero, producing a more concentrated and shorter impact interval for the disengagement vibration. By adjusting the duration ratio of the three stages, asymmetric vibration waveforms with different impact densities can be generated while ensuring that the vibration frequency and amplitude meet the requirements. This waveform control function is implemented by the timer and high-speed output module within the PLC controller, updating the target rotational speed value sequentially at preset time nodes within one vibration cycle.

[0046] When the vibration device operates with the aforementioned combination of unlocking parameters, the periodic centrifugal force generated by the eccentric rotation of the rotating plate 17 is transmitted to the bottom plate of the storage bin 3 through the mounting flange of the drive motor 18 and the support block 20. A rigid force transmission path is formed between the bottom plate of the storage bin 3 and the two T-shaped blocks 5 via the side wall of the storage bin 3. The vibration force propagates along this path in the form of stress waves, ultimately acting on the mating gap area between the outer contour surface of the T-shaped block 5 and the inner contour surface of the T-shaped groove 4. The mating gap area is the specific location where jamming occurs. Under normal conditions, this gap contains micron- to tens of micron-sized gaps, allowing the T-shaped block 5 to slide smoothly within the T-shaped groove 4. Under jamming conditions, the gap is locally squeezed and closed or foreign particles are embedded, forming a contact stress concentration area.

[0047] Under the action of disengagement vibration, the T-block 5 generates low-frequency large-amplitude vibrations in a vertical plane parallel to the extension direction of the T-shaped groove 4, with vibration amplitudes ranging from tens to hundreds of micrometers. The mechanical effect of this vibration is manifested on two levels: First, when the T-block 5 vibrates upward to the positive displacement peak, the contact pressure on the jamming point on the inner wall of the T-shaped groove 4 increases instantaneously, causing elastic deformation or even micro-plastic deformation of the material in the compression contact area, storing strain energy; when the T-block 5 vibrates downward to the negative displacement peak, the contact pressure decreases instantaneously or even disappears, the stored strain energy is released, and accompanied by the elastic recovery of the local material, allowing the high-stress area around the jamming point to undergo a complete loading and unloading cycle. After several to dozens of vibration cycles of repeated loading and unloading, the initial stress concentration distribution gradually becomes uniform, the contact stress at the local jamming point drops below the material yield strength, and the relative motion capability between the T-block 5 and the T-shaped groove 4 is restored. Second, if the jamming is caused by hard foreign particles embedded in the gap, the large reciprocating motion of the T-block 5 will continuously change the force direction and contact geometry of the foreign particles, causing the particles to experience various motion modes such as rolling, sliding and flipping in the gap, gradually adjusting from the embedded posture to the non-embedded posture, and finally being pushed to the wide area of ​​the gap or completely detached from the contact area, thereby eliminating the jamming.

[0048] In a preferred embodiment, during the unlocking process, the driving current of the crane and / or the real-time tension value of the driving wire rope are continuously acquired, and the following unlocking exit logic is executed: At the same moment the card-unlocking vibration is initiated, the fluctuation threshold in the second judgment condition is automatically increased by a preset ratio to offset the periodic fluctuation interference introduced by the vibration device itself on the monitoring parameters. If, within the preset unblocking evaluation window, the monitoring parameters no longer simultaneously meet the first judgment condition and the second judgment condition after floating, the unblocking is determined to be successful. The vibration device is controlled to stop, and the crane is controlled to continue lifting at a preset recovery speed lower than the operating speed before the blockage. During the recovery lifting process, the monitoring parameters are continuously acquired. If the monitoring parameters again simultaneously meet the first judgment condition and the second judgment condition after floating, a secondary blockage is determined to have occurred. The crane is immediately paused and re-enters the unblocking mode. If, within the card-unlocking evaluation window, the monitoring parameters still simultaneously meet the first judgment condition and the second judgment condition after floating, then the single card-unlocking attempt is determined to be unsuccessful. The vibration device is then controlled to gradually increase the vibration frequency and / or amplitude by a preset increment step and then the card-unlocking vibration is performed again until the preset maximum card-unlocking strength limit is reached or the card-unlocking is successful. If, after reaching the maximum unlocking strength limit, the monitoring parameters still simultaneously meet the first judgment condition and the second judgment condition after floating, then the unlocking is determined to have failed, the crane is controlled to stop running, and a first type of fault alarm signal is output.

[0049] Specifically, at the same moment the PLC controller initiates the card-unlocking vibration of the vibration device, the PLC controller automatically increases the fluctuation threshold in the second judgment condition by a preset ratio. The specific execution method is as follows: the PLC controller maintains a reference value for the fluctuation threshold in its memory, which is statistically calibrated under normal lifting conditions of the storage silo 3. When the card-unlocking vibration start command is issued, the PLC controller multiplies this reference value by a preset upward coefficient to obtain the increased fluctuation threshold, and replaces the currently effective fluctuation threshold in the second judgment condition with this increased value. The upward coefficient typically ranges from 1.5 to 3, and the specific value is determined experimentally based on the vibration intensity of the vibration device under the card-unlocking parameter combination. The physical necessity of the upward operation lies in the fact that after the vibration device is started, the drive motor 18 drives the rotating plate 17 to rotate eccentrically. The resulting periodic vibration force not only acts on the mating gap between the T-shaped block 5 and the T-shaped slide 4, but also simultaneously transmits it in the reverse direction to the overall structure of the storage silo 3, and then through the lifting steel cable to the crane 8. This conduction introduces periodic fluctuation components with the same frequency as the vibration into the drive current and wire rope tension signals of crane 8. If the fluctuation threshold is not raised, this normal fluctuation caused by vibration is easily judged as a jamming characteristic signal by the second judgment condition, causing the PLC controller to continuously judge that the jamming has not been resolved, and the unlocking exit logic will never enter the successful branch. The raised threshold is higher than the interference fluctuation amplitude introduced by the vibration device itself, thus eliminating this source of misjudgment. During the continuous operation of the unlocking vibration, the PLC controller sets a preset unlocking evaluation window. The unlocking evaluation window is a judgment period in units of time, and its length is usually set to an integer multiple of the vibration period to ensure that the window contains a complete number of vibration cycles and avoid evaluation deviations caused by the inconsistency between the window boundary and the vibration phase. At the end of an unlocking evaluation window, the PLC controller counts whether the monitoring parameters in the window still simultaneously meet the first judgment condition and the second judgment condition after the raising.

[0050] If, within a single unblocking evaluation window, the monitored parameters no longer simultaneously meet both the first judgment condition and the second judgment condition after floating, the PLC controller determines that the unblocking is successful. After successful unblocking, the PLC controller immediately executes the following steps: First, it outputs a stop command to the motor driver of the drive motor 18, cutting off the power supply to the drive motor 18, causing the rotating plate 17 to stop rotating and the vibration device to exit the unblocking mode; Second, it re-outputs a run command to the frequency converter or contactor of the crane 8, controlling the crane 8 to continue lifting the storage bin 3 at a preset recovery speed lower than the pre-blocking running speed. The preset recovery speed is typically set to 50% to 80% of the pre-blocking running speed. The purpose of using a lower speed for recovery is that although the blockage has been resolved, there may still be localized increased roughness or trace foreign matter residue between the T-block 5 and the T-groove 4. Running at a lower speed reduces the risk of re-blocking and provides sufficient monitoring response time for the PLC controller. During the recovery and lifting process, the PLC controller continuously acquires the drive current of the crane 8 and the real-time tension value of the wire rope, and continuously compares it with the first judgment condition and the second judgment condition after floating. If, during the recovery and lifting process, the monitored parameters once again simultaneously meet the first judgment condition and the second judgment condition after floating, the PLC controller determines that a secondary jamming has occurred. Secondary jamming refers to the situation where, after the T-block 5 has successfully unjammed and resumed lifting, it jams again in a new position within a short period of time because the cause of the jamming has not been completely eliminated or the local condition of the slide has deteriorated. After determining secondary jamming, the PLC controller immediately pauses the operation of the crane 8 and re-enters the unjamming mode, starting a new round of unjamming vibration from the initial intensity of the unjamming parameter combination.

[0051] If, within a single unblocking evaluation window, the monitored parameters simultaneously meet both the first judgment condition and the second judgment condition (after adjustment), the PLC controller determines that the single unblocking attempt has failed. A single unblocking attempt indicates that the current vibration parameters are insufficient to eliminate the jamming, and the unblocking intensity needs to be increased. The PLC controller gradually increases at least one parameter of the vibration frequency and amplitude according to a preset increment step. The principle for setting the increment step is: each increase should be sufficient to produce a identifiable difference in unblocking effect, but should not be too large to cause a sudden change in the load on the vibration device or to cause impact on the structure. A typical increment step is an increase in amplitude of 5% to 10% of the maximum amplitude, or a decrease in frequency of 1 to 3 Hz. After increasing the vibration intensity, the PLC controller restarts a new unblocking evaluation window and performs the unblocking vibration and effect evaluation again.

[0052] The above-mentioned amplification process is repeated until the preset maximum unlocking strength limit is reached or the unlocking is successful. The maximum unlocking strength limit refers to the upper limit of the intensity within the safe operating range of the vibration device. The corresponding parameter combination is usually that the vibration frequency is reduced to 15Hz and the vibration amplitude reaches 100% of the maximum amplitude. If, after a complete unlocking evaluation window in which the current intensity has reached the maximum unlocking strength limit, the monitoring parameters still simultaneously meet the first judgment condition and the second judgment condition after floating, the PLC controller determines that the unlocking has failed. After the unlocking failure is determined, the PLC controller performs the following steps: controls the crane 8 to stop running and cuts off the power supply to the crane 8 motor; drives the alarm indicator light or buzzer through the digital output module, or sends an alarm message to the host computer through the communication interface, and outputs the first type of fault alarm signal. The first type of fault alarm signal is used to prompt the operator that the T-block 5 has a serious jam that cannot be eliminated by automatic unlocking and requires manual intervention, such as checking whether there are large foreign objects or structural deformations in the T-shaped groove 4.

[0053] In a preferred embodiment, during the card unlocking process: The single card-unlocking vibration within the card-unlocking evaluation window constitutes the inner ring adjustment layer, and the vibration frequency and / or amplitude are gradually increased according to the preset increase step size to constitute the outer ring adjustment layer; the inner ring adjustment layer is effective in real time during a single card-unlocking vibration, and the outer ring adjustment layer is only triggered to update after the card-unlocking evaluation window of the previous card-unlocking vibration ends, and the two do not act on the same vibration cycle at the same time. During the single card release vibration, the crane is controlled to apply a periodic pulsating auxiliary lifting force to the storage bin in sync with the vibration excitation signal of the vibration device. The amplitude of the pulsating auxiliary lifting force does not exceed 10% of the rated lifting force of the crane, and the lifting force pulse is applied during the return phase of the vibration device in each vibration cycle.

[0054] Specifically, during the card unlocking process, the PLC controller divides the adjustment logic into two layers: an inner and an outer layer. These two layers have different triggering times and effective ranges to resolve potential conflicts in parameter adjustment commands over time. The inner layer is defined as a single card unlocking vibration process within the card unlocking evaluation window. Throughout the entire period from the start of a card unlocking vibration to the end of the evaluation window, the inner layer operates continuously and takes effect in real time. During this single card unlocking vibration, the inner layer is responsible for fine-tuning the vibration parameters at the millisecond level based on real-time feedback signals. Its adjustment step size is small, and its adjustment frequency is high.

[0055] The outer loop adjustment layer is defined as a step-by-step enhancement logic that gradually increases the vibration frequency and amplitude according to a preset increment step. The triggering time of the outer loop adjustment layer is strictly limited to after the end of the previous card unlocking vibration unlocking evaluation window. Only when a complete card unlocking evaluation window ends and the PLC controller determines that the single card unlocking attempt was unsuccessful within that window, will the outer loop adjustment layer trigger an update, adjusting the vibration frequency and amplitude to a new enhancement value according to the increment step as described in claim 4, and using this enhancement value as the initial vibration parameter for the next card unlocking evaluation window.

[0056] The specific implementation of the inner and outer loop layering is as follows: The PLC controller sets two independent sets of vibration parameter registers in memory: one is the outer loop reference parameter register, and the other is the inner loop real-time parameter register. The value of the outer loop reference parameter register is updated only once by the outer loop adjustment layer at the end of the card unlocking evaluation window. The initial value of the inner loop real-time parameter register is loaded from the outer loop reference parameter register at the beginning of each card unlocking evaluation window. During the window operation, the inner loop adjustment layer modifies it in real time according to the feedback signal. This modification only affects the vibration output within the current window and is not written back to the outer loop reference parameter register. When the card unlocking evaluation window ends, if it is determined that the single card unlocking attempt has failed, the outer loop adjustment layer updates the outer loop reference parameter register and then loads it into the inner loop real-time parameter register again at the beginning of the next window, starting a new round of inner loop adjustment. Thus, the low-frequency step-by-step update of the outer loop adjustment layer and the high-frequency real-time fine-tuning of the inner loop adjustment layer are physically isolated at the data flow level. The two do not act on the same vibration cycle at the same time, and there will be no parameter instruction conflict where the outer loop is increasing the amplitude while the inner loop is decreasing the amplitude.

[0057] During a single card release vibration, the PLC controller also synchronously executes a pulse-assisted lifting strategy. This strategy is implemented as follows: the PLC controller uses its internal timer resources to generate a pulse signal synchronized with the vibration excitation signal. The frequency and phase information of the vibration excitation signal are generated by the PLC controller itself, since the vibration frequency is determined by the speed command output by the PLC controller to the motor driver of the drive motor 18. Therefore, the PLC controller naturally possesses the real-time frequency and phase information of the vibration excitation signal. Based on this phase information, the PLC controller accurately determines the start and end times of the return phase within each vibration cycle. The return phase refers to the period within one rotation cycle when the centrifugal force vector of the rotating plate 17 deviates from the direction of the T-shaped chute 4, and the T-shaped block 5 has a downward movement tendency or a decrease in upward contact pressure within the chute. During the duration of the return phase, the PLC controller outputs a small target speed increment to the crane 8 motor via the frequency converter, or outputs a small torque command increment to the crane 8 motor driver via the analog output module. This increment causes the lifting force applied by the crane 8 to the storage bin 3 to increase pulsatiously at a low amplitude. The amplitude of the pulsating auxiliary lifting force is strictly controlled to not exceed 10% of the rated lifting force of the crane 8. The purpose of this low amplitude setting is that the lifting force is only used to generate a small upward displacement accumulation during the gap when the contact pressure between the T-block 5 and the T-shaped chute 4 decreases, rather than forcibly lifting the entire storage bin 3. This avoids excessive contact stress on the upper wall of the chute due to the superposition of vibration impact stroke and vibration force caused by excessive lifting force. The lifting force pulse is applied during the return phase of each vibration cycle and stops during the impact phase, so that the direction of the lifting force and the direction of the vibration force are staggered in the time dimension, avoiding the two forces from superimposing in space and causing reverse cancellation or aggravating wear.

[0058] In a preferred embodiment, during a single card release vibration, the PLC controller also performs the following closed-loop optimization steps: The AC component of the crane drive current is continuously collected, and the phase lag angle of the AC component of the drive current relative to the vibration excitation signal of the vibration device is calculated in real time. Closed-loop adjustment is performed using the phase lag angle as feedback: when the phase lag angle is greater than the preset jamming threshold, it indicates that the jamming has not loosened. The vibration device is controlled to continuously reduce the vibration frequency and simultaneously increase the vibration amplitude by a preset step size until the phase lag angle is reduced to below the jamming threshold. When the phase lag angle decreases to below the jamming threshold, it is determined that the jamming has loosened, the parameter adjustment is stopped, and the current vibration parameters are used to continue running for a preset consolidation time before exiting the current unblocking vibration. The closed-loop adjustment has a safety boundary: when the vibration frequency decreases to the preset minimum allowable frequency or the vibration amplitude increases to the maximum allowable amplitude of the vibration device, the parameter adjustment is stopped and the current parameters are maintained until the current card unlocking vibration ends.

[0059] Specifically, during a single card release vibration, while controlling the operation of the vibration device, the AC component of the crane 8 drive current is continuously collected via a current sensor. The acquisition method of the AC component is consistent with the high-pass filtering processing method of the second judgment condition, employing a first-order infinite impulse response digital high-pass filter to filter out the DC component and low-frequency trend term in the drive current signal, retaining only the periodic fluctuation component related to the vibration frequency. The high-pass filter output value is the real-time value of the AC component of the drive current.

[0060] The phase lag angle of the AC component of the drive current relative to the vibration excitation signal is calculated in real time. Specifically, a sinusoidal reference signal with the same frequency as the vibration excitation signal is maintained in memory. The phase of this reference signal is obtained by integrating the vibration frequency instruction output by the PLC controller itself, representing the real-time phase of the vibration excitation. Simultaneously, the PLC controller performs zero-crossing detection or quadrature demodulation processing on the AC component of the drive current, extracting its phase difference relative to the sinusoidal reference signal. When the T-block 5 and the T-slot 4 are tightly jammed, the slight auxiliary lifting force applied by the crane 8 cannot cause the T-block 5 to follow the movement. The AC component of the drive current is mainly contributed by the vibration reaction force, and its phase is almost in phase with the vibration excitation, resulting in a small phase lag angle. As the vibration continues to act, the T-block 5 gradually loosens, allowing it to move slightly. The auxiliary lifting force of the crane 8 then drives the T-block 5 to produce a small displacement response. The mechanical inertia of this displacement response causes the AC component of the driving current to lag detectably relative to the vibration excitation signal, and the lag angle gradually increases.

[0061] The PLC controller uses the calculated phase lag angle as feedback to perform closed-loop regulation. The deviation of the closed-loop regulation is the difference between the current phase lag angle and the preset jamming threshold. The jamming threshold is a phase lag angle value calibrated experimentally. When the phase lag angle is below the threshold, it indicates that the T-block 5 is still in a basically jammed state; when the phase lag angle exceeds the threshold, it indicates that the T-block 5 has gained sufficient room to move and the jamming has been substantially loosened. The control quantities of the closed-loop regulation are the vibration frequency and vibration amplitude of the vibration device. The adjustment direction is as follows: when the phase lag angle is greater than the jamming threshold, it indicates that the jamming has not yet loosened. The PLC controller outputs a lower speed command to the motor driver of the drive motor 18 to reduce the vibration frequency, and at the same time outputs a higher peak speed command to increase the vibration amplitude. The frequency is continuously reduced and the amplitude is increased by a preset step size until the phase lag angle is reduced below the jamming threshold. The preset step size is relatively small, with the frequency step size typically ranging from 0.5 to 2 Hz and the amplitude step size typically ranging from 3% to 5% of the maximum amplitude, to ensure a smooth adjustment process and avoid mechanical shock caused by sudden parameter changes.

[0062] When the phase lag angle decreases below the jamming threshold, the jamming is determined to be loose. Loosening of the jamming means that the jammed contact state of T-block 5 within T-groove 4 has been substantially weakened. Although the current unblocking evaluation window has not yet ended and the unblocking exit logic has not yet given a final success determination, the inner loop closed-loop adjustment has detected an improvement in the jamming state. At this time, the PLC controller stops parameter adjustment, locks the current vibration frequency and amplitude, and continues to run with these locked vibration parameters for a preset consolidation period. The purpose of the consolidation period is to ensure that after detecting loosening of the jamming, the vibration does not stop immediately, but continues to run with the current effective parameters for a period of time, ensuring that the loosening state between T-block 5 and T-groove 4 is fully consolidated, avoiding repeated jamming. After the consolidation period ends, the PLC controller exits this unblocking vibration, and the outer unblocking exit logic performs the final unblocking success determination.

[0063] The closed-loop control is equipped with safety boundaries to prevent the vibration device from exceeding its safe operating range if the phase lag angle cannot be reduced below the jamming threshold. Specifically, the safety boundaries include: a lower safety limit for frequency, set as the lowest frequency at which the vibration device can operate stably under rated conditions, determined by the minimum stable speed of the drive motor 18 and the mechanical characteristics of the rotating plate 17; and an upper safety limit for amplitude, set as the maximum permissible amplitude of the vibration device, determined by the eccentricity of the rotating plate 17 and the upper limit of the rated speed of the drive motor 18. When the vibration frequency decreases to the minimum permissible frequency or the vibration amplitude increases to the maximum permissible amplitude, even if the phase lag angle has not reached the jamming threshold, the PLC controller stops adjusting the parameters and maintains the current parameters until the current unblocking vibration ends. This prevents the drive motor 18 from overloading and burning out due to exceeding the equipment's limits or the rotating plate 17 from being mechanically damaged due to excessive centrifugal force.

[0064] In a preferred embodiment, the control method further includes: prohibiting the activation of the auxiliary unloading mode while the storage bin has not reached the preset unloading position; and prohibiting the crane from performing lifting and lowering actions during the operation of the auxiliary unloading mode.

[0065] Specifically, the conditions for setting the unloading assistance enable flag are: the storage bin 3 has reached the preset unloading position, the discharge pipe 11 has rotated to the unloading posture, and it is not currently in the unblocking mode. During the period when the storage bin 3 has not reached the preset unloading position, the unloading assistance enable flag is always in the reset state. The PLC controller first checks the status of this flag at the vibration start logic entry point of the auxiliary unloading mode. If it is in the reset state, it skips the execution, thus completely preventing the auxiliary unloading vibration from being mistakenly started in the half-lifting position from the program level.

[0066] The conditions for setting the crane lifting enable flag are: the PLC controller detects that the storage bin 3 is within the lifting range between the initial position and the unloading position, is not currently in auxiliary unloading mode, and is not in unlocking mode. During operation in auxiliary unloading mode, the crane lifting enable flag is forcibly reset. The PLC controller checks the status of this flag before outputting the lifting command of the crane 8. If it is in the reset state, no lifting command is output, and the crane 8 remains stationary.

[0067] The interlocking relationship between the two flags is managed uniformly by the PLC controller at the beginning of the program scan cycle. Simultaneously with the activation of the auxiliary unloading mode, the PLC controller resets the crane lifting enable flag; simultaneously with the activation of the unlocking mode, it resets the unloading auxiliary enable flag. This program-level interlocking, achieved through the enable flags, has a response speed determined by the PLC controller's scan cycle, typically within milliseconds, providing effective safety protection for the device in case of operator error or external signal interference.

[0068] When the storage bin 3 is in a semi-lifting state, the contact position and stress state of the T-shaped block 5 within the T-shaped chute 4 are dynamically changing. If the auxiliary unloading vibration is accidentally activated at this time, the vibration force will be transmitted to the T-shaped block 5 through the side wall of the storage bin 3, superimposing bidirectional alternating stress on the contact surface of the guide rail of the T-shaped chute 4, accelerating wear and potentially inducing new jamming. During operation in the auxiliary unloading mode, the discharge pipe 11 overlaps the edge of the top opening of the color mixer 1. If the crane 8 malfunctions and causes the storage bin 3 to lift or lower, the discharge pipe 11 may detach from the overlap position, causing material spillage. The interlocking mechanism eliminates the possibility of the above-mentioned dangerous conditions from the control logic level.

[0069] In a preferred embodiment, the real-time acquisition of the discharge detection signal reflecting the material outflow status includes the following steps: The initial discharge detection signal is acquired by the first sensor installed at the outlet end of the discharge pipe according to a preset sampling period; at the same time, the frequency and phase information of the current vibration excitation signal of the vibration device are acquired in real time. Using the frequency of the vibration excitation signal as a reference, the initial discharge detection signal is subjected to adaptive notch filtering to filter out periodic interference components with the same frequency as the vibration excitation signal, thereby obtaining an intermediate signal after vibration decoupling. The intermediate signal is compared with the AC component of the driving current of the crane in the auxiliary unloading mode in the time domain: only when the intermediate signal shows pulse characteristics and the AC component of the driving current does not show impact fluctuation characteristics related to the collapse of the material bridging at the corresponding time, the current pulse of the intermediate signal is determined to be a valid discharge pulse. The cumulative number of effective discharge pulses, pulse interval, or duty cycle are used as the discharge detection signal reflecting the material outflow status.

[0070] Specifically, the first step involves acquiring an initial discharge detection signal at a preset sampling period using a first sensor installed at the outlet end of the discharge pipe 11. When the first sensor is a through-beam photoelectric sensor, its transmitter and receiver are respectively installed on opposite sides of the outlet cross-section of the discharge pipe 11. As plastic particles pass through, they block the light, causing a level change in the receiver's output. When the first sensor is a microwave flow switch, it emits microwaves into the discharge pipe 11 and receives reflected waves. The change in dielectric constant caused by the material passing through alters the amplitude or phase of the reflected wave, and the internal circuit converts this change into a switching signal. The PLC controller acquires this signal via digital input or high-speed counting, forming a pulse sequence of the initial discharge detection signal.

[0071] Synchronous with the initial discharge detection signal acquisition, the frequency and phase information of the current vibration excitation signal of the vibration device are obtained from the internal system in real time. Since the vibration frequency itself is determined by the speed command output by the PLC controller to the motor driver of the drive motor 18, it naturally possesses the real-time value of this information, eliminating the need for additional sensors.

[0072] The second step involves adaptive notch filtering of the initial discharge detection signal, using the frequency of the vibration excitation signal as a reference. A notch filter is a digital filter that can significantly attenuate at a specific frequency while having almost no effect on other frequency components. Its difference equation is that the output value equals the input value plus twice the pole coefficient multiplied by the output value of the previous cycle minus the output value of the previous cycle, where the notch frequency is determined by the filter coefficients. The PLC controller updates the notch filter coefficients in real time based on the current vibration excitation signal frequency, ensuring that the notch frequency always tracks the vibration frequency. When the pulse sequence of the initial discharge detection signal contains a periodic interference component consistent with the vibration frequency, this interference component is significantly attenuated by the filter, resulting in an intermediate signal after vibration decoupling. The physical source of this interference component is: during the operation of the vibration device, the vibration force generated by the eccentric rotation of the rotating plate 17 is transmitted through the storage bin 3 to the discharge pipe 11, causing the discharge pipe 11 to produce mechanical vibration at the same frequency as the vibration. This vibration may cause the first sensor to generate a false material passage signal.

[0073] The third step is to perform a time-domain comparison between the intermediate signal and the AC component of the drive current of crane 8 in the auxiliary unloading mode. The acquisition method of the AC component of the drive current is the same as that of the high-pass filtering method. The specific method of time-domain comparison is as follows: when a pulse characteristic appears in the intermediate signal, check whether the AC component of the drive current exhibits impact fluctuation characteristics related to material bridging collapse within a preset time window containing the pulse moment. The impact fluctuation characteristics of material bridging collapse are manifested as a single-peak pulse in which the amplitude of the AC component of the drive current first increases and then decreases within a short period of time. The rise rate and peak value of this pulse exceed the preset bridging collapse judgment threshold. When the bridging collapses, the bridging structure in the storage bin 3 suddenly breaks down, and a large amount of material rushes to the discharge hole 10 in a short period of time. The overall weight of the storage bin 3 changes abruptly, and the tension of the lifting steel cable changes accordingly, thereby generating a detectable impact signal in the crane drive current. If the AC component of the driving current exhibits this impact fluctuation characteristic within the corresponding window of the pulse moment, it indicates that the discharge pulse may be a sudden surge of material caused by the collapse of the bridge structure, rather than a stable continuous flow. This pulse should be marked as invalid and not counted. Only when the intermediate signal exhibits pulse characteristics and the AC component of the driving current does not show the impact characteristics of a bridge collapse at the corresponding moment will the current pulse be determined as a valid discharge pulse.

[0074] Fourth, the PLC controller uses the cumulative number of valid discharge pulses, the interval between adjacent pulses, or the duty cycle of valid discharge pulses as discharge detection signals to reflect the material outflow status. The cumulative number reflects the total trend of material outflow over a certain period of time, the pulse interval reflects the continuity and uniformity of material outflow, and the duty cycle reflects the density of material outflow.

[0075] In a preferred embodiment, the vibration frequency, vibration amplitude, and intermittent impact duty cycle of the asymmetric waveform in the card unlocking parameter combination are determined by the PLC controller according to the following steps when the card unlocking mode is activated: The peak value and peak rise time of the shock wave of the monitoring parameters are traced back one preset feature extraction window from the instant the trigger jamming judgment condition is extracted. The peak value of the shock wave is compared with multiple preset peak classification thresholds to generate a peak level that reflects the magnitude of the jamming resistance; the rise time of the shock wave peak is compared with multiple preset time classification thresholds to generate a time level that reflects the suddenness of the jamming. The peak level is given as the first priority and the time level as the second priority. The two are combined into a comprehensive jamming stiffness index, which monotonically increases as the peak level and time level increase.

[0076] Specifically, at the instant the jamming is determined and the de-jamming mode is initiated, data within a preset feature extraction window is extracted from the circular buffer storing the monitoring parameters, tracing back from the moment the jamming determination was triggered. The length of the feature extraction window is typically set to cover a short window for the first determination condition and a medium window for the second determination condition, ensuring that the complete jamming process signal is included. The position of the shock wave peak is located within this window; this peak is the maximum value of the monitoring parameter identified when the first determination condition is triggered, and its peak value is recorded as the shock wave peak value, in amperes or newtons. Simultaneously, tracing back from the shock wave peak, the starting point where the monitoring parameter begins to rise is found, and the time taken from this starting point to the peak of the shock wave is calculated and recorded as the shock wave peak rise time, in milliseconds. The shock wave peak value reflects the intensity of the load impact of the crane 8 when the jamming occurs; a larger peak value indicates a tighter engagement at the moment of jamming. The shock wave peak rise time reflects the suddenness of the jamming; a shorter rise time indicates a more sudden and more rigid jamming.

[0077] The peak value of the shock wave is compared with multiple preset peak value classification thresholds. These thresholds are a set of experimentally calibrated current or force values. For example, the first peak value corresponds to the upper limit of impact intensity for mild jamming, the second peak value corresponds to the upper limit of impact intensity for moderate jamming, and so on. The comparison proceeds step-by-step from the lowest threshold. When a peak value exceeds a certain threshold but does not exceed the next lower threshold, the corresponding level value is determined as the peak value; the larger the peak value, the higher the peak value.

[0078] The rise time of the shock wave peak is compared with several preset time-level thresholds. These thresholds are also experimentally calibrated; for example, the first time threshold corresponds to the lower limit of the time for slow stalling, and the second time threshold corresponds to the lower limit of the time for moderate stalling. The shorter the rise time, the higher the corresponding level value and the higher the time level.

[0079] The peak level is prioritized first, and the time level is prioritized second, and the two are merged into a comprehensive hysteresis stiffness index. The specific fusion method is as follows: the peak level is treated as the high-order component of the index, and the time level as the low-order component. For example, the peak level is multiplied by a base greater than the maximum value of the time level, and then the time level is added, so that the difference in peak level has a greater weight on the index than the time level. The comprehensive hysteresis stiffness index monotonically increases with both the peak level and the time level. The physical meaning of this index is to integrate the severity (resistance magnitude) and type characteristics (sudden occurrence) of hysteresis into an ordered one-dimensional decision quantity.

[0080] In a preferred embodiment, the vibration frequency, vibration amplitude, and intermittent impact duty cycle in the unlocking parameter combination are determined according to the comprehensive jamming stiffness index according to the following rules: The larger the comprehensive sticking stiffness index, the closer the vibration frequency value is to the lower limit of the preset frequency range of the unlocking mode, the closer the vibration amplitude value is to the maximum amplitude of the vibration device, and the closer the intermittent impact duty cycle value is to zero. The smaller the comprehensive sticking stiffness index, the closer the vibration frequency value is to the upper limit of the preset frequency range of the unlocking mode, the closer the vibration amplitude value is to 70% of the maximum amplitude, and the closer the intermittent impact duty cycle value is to the preset maximum duty cycle limit. The lower and upper limits of the frequency range, as well as 70% of the maximum amplitude and the maximum duty cycle limit, are all within the range of the card unlocking parameter combination.

[0081] After obtaining the comprehensive jamming stiffness index, the PLC controller determines three parameters in the de-jamming parameter combination according to the monotonic mapping rule. Monotonic mapping means that there is a unidirectional relationship between the comprehensive jamming stiffness index and each parameter, without reversal or inflection points.

[0082] Regarding vibration frequency: The larger the comprehensive jamming stiffness index, the closer the vibration frequency is to the lower limit of the preset frequency range of the unlocking mode, i.e., 15Hz. The mapping method involves normalizing the comprehensive jamming stiffness index to a mapping coefficient between zero and one. The frequency value is equal to the lower limit of 15Hz plus the difference between the upper limit of 35Hz and the lower limit of 15Hz multiplied by one minus the mapping coefficient. The larger the index, the larger the mapping coefficient, and the closer the frequency is to 15Hz. At a lower frequency, under the condition of a fixed output power of the vibration device, a larger single impact stroke can be generated, allowing the T-block 5 to obtain a larger displacement amplitude to overcome strong jamming. The smaller the comprehensive jamming stiffness index, the closer the frequency is to the upper limit of 35Hz, allowing for faster processing of mild jamming with a higher frequency and lower amplitude, avoiding excessive vibration.

[0083] Regarding vibration amplitude: the larger the comprehensive hysteresis stiffness exponent, the closer the vibration amplitude is to the maximum amplitude of the vibrating device. The mapping method is that the amplitude value equals the maximum amplitude multiplied by a proportionality coefficient positively correlated with the exponent. When the exponent is at its maximum, the proportionality coefficient is one, and the amplitude reaches the maximum; when the exponent is at its minimum, the proportionality coefficient is 0.7, and the amplitude is 70% of the maximum amplitude. A high amplitude can provide a larger peak vibration force, enabling the contact stress in the hysteresis region to generate a sufficiently large loading and unloading amplitude to eliminate stress concentration.

[0084] For intermittent impact duty cycle: the larger the comprehensive jamming stiffness index, the closer the duty cycle value is to zero. The duty cycle is defined as the ratio of the impact segment duration to the entire vibration cycle duration. Approaching zero means that the impact segment is extremely short, the interval is extremely short, and the impact sequence is extremely dense. The dense impact sequence can apply more impacts to the T-block 5 per unit time, accelerating the stress relaxation and foreign object redistribution in the jammed area. The smaller the comprehensive jamming stiffness index, the closer the duty cycle value is to the preset maximum duty cycle limit. This maximum duty cycle limit is within the allowable range of the unlocking parameter combination, corresponding to a longer impact interval, handling mild jamming with a gentler impact rhythm.

[0085] The frequency lower limit of 15Hz, upper limit of 35Hz, maximum amplitude of 70%, and maximum duty cycle limit involved in the above mapping are all within the range of the card unlocking parameter combination. The PLC controller writes the three parameter values ​​obtained from the mapping into the control instruction register of the drive motor 18, and the vibration device starts the card unlocking vibration according to the parameter combination.

[0086] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A control method for an automatic feeding device of a high-efficiency plastic color mixing machine, applied to the automatic feeding device; the automatic feeding device includes: A color mixing machine with an opening at the top; The first fixed plate is vertically fixed to the side wall of the color mixing machine, and a T-shaped groove extending in the vertical direction is provided on it; The storage bin is slidably fitted into the T-shaped groove by a T-shaped block. The bottom of the storage bin is inclined and a discharge hole is opened at the lower end. A rotatable discharge pipe is connected to the discharge hole. A crane is fixed to the upper part of the first fixed plate and connected to the storage silo via lifting steel cables; A vibration device is installed at the bottom of the storage bin to apply vibration to the storage bin; The PLC controller is electrically connected to both the crane and the vibration device. The control method is characterized by being executed by the PLC controller and includes the following steps: The crane is controlled to drive the storage bin to move up and down along the T-shaped chute, and monitoring parameters reflecting the load of the crane are acquired in real time during this process; When the monitored parameters meet the preset jamming judgment conditions, the crane is controlled to pause or decelerate, and the vibration device is activated to work in the preset unblocking mode; after the unblocking is completed, the crane is controlled to resume operation. When the storage bin is detected to have reached the preset unloading position, the discharge pipe is controlled to rotate to the unloading posture, and the discharge detection signal reflecting the material outflow status is acquired in real time. When the discharge detection signal indicates that the material flow is not smooth, the vibration device is activated to assist the unloading mode; when the material resumes continuous flow or the preset conditions are met, the vibration device is stopped.

2. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 1, characterized in that, The monitoring parameters reflecting the load of the crane include the crane's drive current and / or the real-time tension value of the drive wire rope; The preset jamming determination conditions include at least one of the following: First determination condition: The real-time sampled value of the monitoring parameter shows a shock wave peak with an upward slope exceeding a preset slope threshold within the first preset short window, and the peak value of the shock wave peak exceeds a certain multiple of the preset dynamic reference value. Second determination condition: After the real-time sampled value of the monitoring parameter is processed by high-pass filtering, the AC component fluctuation amplitude obtained within the second preset time window exceeds the preset fluctuation threshold multiple times consecutively. If the monitoring parameters simultaneously meet the first and second determination conditions, it is determined that the T-shaped block is momentarily stuck in the T-shaped groove and tends to become continuously stuck.

3. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 2, characterized in that, The card unlocking modes include: The vibration device is controlled to operate with a preset combination of unlocking parameters; the combination of unlocking parameters includes: a vibration frequency range of 15Hz to 35Hz in the low frequency range, a vibration amplitude of 70% to 100% of the maximum amplitude of the vibration device, and a vibration waveform of an asymmetric waveform with intermittent impact characteristics. When the vibration device operates with the aforementioned unblocking parameter combination, the generated vibration force is transmitted through the bottom plate of the storage bin to the mating gap between the T-shaped block and the T-shaped groove, causing the T-shaped block to produce low-frequency large-amplitude vibrations parallel to the extension direction of the groove, thereby eliminating local stress concentrations or instantaneous foreign object embedding that cause jamming.

4. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 3, characterized in that, During the unlocking process, the driving current of the crane and / or the real-time tension value of the driving wire rope are continuously acquired, and the following unlocking exit logic is executed: At the same moment the card-unlocking vibration is initiated, the fluctuation threshold in the second judgment condition is automatically increased by a preset ratio to offset the periodic fluctuation interference introduced by the vibration device itself on the monitoring parameters. If, within the preset unblocking evaluation window, the monitoring parameters no longer simultaneously meet the first judgment condition and the second judgment condition after floating, the unblocking is determined to be successful. The vibration device is controlled to stop, and the crane is controlled to continue lifting at a preset recovery speed lower than the operating speed before the blockage. During the recovery lifting process, the monitoring parameters are continuously acquired. If the monitoring parameters again simultaneously meet the first judgment condition and the second judgment condition after floating, a secondary blockage is determined to have occurred. The crane is immediately paused and re-enters the unblocking mode. If, within the card-unlocking evaluation window, the monitoring parameters still simultaneously meet the first judgment condition and the second judgment condition after floating, then the single card-unlocking attempt is determined to be unsuccessful. The vibration device is then controlled to gradually increase the vibration frequency and / or amplitude by a preset increment step and then the card-unlocking vibration is performed again until the preset maximum card-unlocking strength limit is reached or the card-unlocking is successful. If, after reaching the maximum unlocking strength limit, the monitoring parameters still simultaneously meet the first judgment condition and the second judgment condition after floating, then the unlocking is determined to have failed, the crane is controlled to stop running, and a first type of fault alarm signal is output.

5. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 4, characterized in that, During the card unlocking process: The single card-unlocking vibration within the card-unlocking evaluation window constitutes the inner ring adjustment layer, and the vibration frequency and / or amplitude are gradually increased according to the preset increase step size to constitute the outer ring adjustment layer; the inner ring adjustment layer is effective in real time during a single card-unlocking vibration, and the outer ring adjustment layer is only triggered to update after the card-unlocking evaluation window of the previous card-unlocking vibration ends, and the two do not act on the same vibration cycle at the same time. During the single card release vibration, the crane is controlled to apply a periodic pulsating auxiliary lifting force to the storage bin in sync with the vibration excitation signal of the vibration device. The amplitude of the pulsating auxiliary lifting force does not exceed 10% of the rated lifting force of the crane, and the lifting force pulse is applied during the return phase of the vibration device in each vibration cycle.

6. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 4, characterized in that, During a single card release vibration, the PLC controller also performs the following closed-loop optimization steps: The AC component of the crane drive current is continuously collected, and the phase lag angle of the AC component of the drive current relative to the vibration excitation signal of the vibration device is calculated in real time. Closed-loop adjustment is performed using the phase lag angle as feedback: when the phase lag angle is greater than the preset jamming threshold, it indicates that the jamming has not loosened. The vibration device is controlled to continuously reduce the vibration frequency and simultaneously increase the vibration amplitude by a preset step size until the phase lag angle is reduced to below the jamming threshold. When the phase lag angle decreases to below the jamming threshold, it is determined that the jamming has loosened, the parameter adjustment is stopped, and the current vibration parameters are used to continue running for a preset consolidation time before exiting the current unblocking vibration. The closed-loop adjustment has a safety boundary: when the vibration frequency decreases to the preset minimum allowable frequency or the vibration amplitude increases to the maximum allowable amplitude of the vibration device, the parameter adjustment is stopped and the current parameters are maintained until the current card unlocking vibration ends.

7. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 1, characterized in that, The control method further includes: prohibiting the activation of the auxiliary unloading mode while the storage hopper has not reached the preset unloading position; and prohibiting the crane from performing lifting and lowering actions while the auxiliary unloading mode is in operation.

8. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 1, characterized in that, The real-time acquisition of the discharge detection signal reflecting the material outflow status includes the following steps: The initial discharge detection signal is acquired by the first sensor installed at the outlet end of the discharge pipe according to a preset sampling period; at the same time, the frequency and phase information of the current vibration excitation signal of the vibration device are acquired in real time. Using the frequency of the vibration excitation signal as a reference, the initial discharge detection signal is subjected to adaptive notch filtering to filter out periodic interference components with the same frequency as the vibration excitation signal, thereby obtaining an intermediate signal after vibration decoupling. The intermediate signal is compared with the AC component of the driving current of the crane in the auxiliary unloading mode in the time domain: only when the intermediate signal shows pulse characteristics and the AC component of the driving current does not show impact fluctuation characteristics related to the collapse of the material bridging at the corresponding time, the current pulse of the intermediate signal is determined to be a valid discharge pulse. The cumulative number of effective discharge pulses, pulse interval, or duty cycle are used as the discharge detection signal reflecting the material outflow status.

9. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 3, characterized in that, The vibration frequency, vibration amplitude, and intermittent impact duty cycle of the asymmetric waveform in the card unlocking parameter combination are determined by the PLC controller according to the following steps when the card unlocking mode is activated: The peak value and peak rise time of the shock wave of the monitoring parameters are traced back one preset feature extraction window from the instant the trigger jamming judgment condition is extracted. The peak value of the shock wave is compared with multiple preset peak classification thresholds to generate a peak level that reflects the magnitude of the jamming resistance; the rise time of the shock wave peak is compared with multiple preset time classification thresholds to generate a time level that reflects the suddenness of the jamming. The peak level is given as the first priority and the time level as the second priority. The two are combined into a comprehensive jamming stiffness index, which monotonically increases as the peak level and time level increase.

10. The control method for the automatic feeding device of the high-efficiency plastic color mixing machine according to claim 9, characterized in that, The vibration frequency, vibration amplitude, and intermittent impact duty cycle in the de-jamming parameter combination are determined according to the comprehensive jamming stiffness index according to the following rules: The larger the comprehensive sticking stiffness index, the closer the vibration frequency value is to the lower limit of the preset frequency range of the unlocking mode, the closer the vibration amplitude value is to the maximum amplitude of the vibration device, and the closer the intermittent impact duty cycle value is to zero. The smaller the comprehensive sticking stiffness index, the closer the vibration frequency value is to the upper limit of the preset frequency range of the unlocking mode, the closer the vibration amplitude value is to 70% of the maximum amplitude, and the closer the intermittent impact duty cycle value is to the preset maximum duty cycle limit. The lower and upper limits of the frequency range, as well as 70% of the maximum amplitude and the maximum duty cycle limit, are all within the range of the card unlocking parameter combination.

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