Static eliminator adaptive multi-stage regulation method, system and product

Abstract

The application relates to the field of electrostatic eliminators, and provides an electrostatic eliminator adaptive multistage regulation method, system and product.The method comprises the following steps: configuring initial working state parameters of an electrostatic eliminator; acquiring an electrostatic potential and a potential polarity of a surface of a material to be eliminated; comparing the electrostatic potential with a preset potential threshold value; if the absolute value of the electrostatic potential is greater than the preset potential threshold value, determining a regulation level according to a deviation degree, and performing hierarchical regulation on ionization state parameters and / or working air flow state parameters according to the regulation level and the potential polarity; continuing operation and cyclic feedback with the regulated parameters until the electrostatic potential meets the standard.The application realizes adaptive closed-loop regulation of working state parameters of the electrostatic eliminator, takes into account fast convergence and fine adjustment through a hierarchical regulation mechanism, realizes associated and cooperative regulation of ionization parameters and air flow parameters, and significantly improves the consistency of the electric elimination effect and the adaptive capacity of the equipment.

Description

Technical Field

[0001] This application relates to the field of static eliminators, specifically to an adaptive multi-level control method, system, and product for static eliminators. Background Technology

[0002] Static eliminators are commonly used devices in industrial production and electronics manufacturing to eliminate static electricity on material surfaces. They are widely applied in industries sensitive to static electricity, such as semiconductor manufacturing, flat panel display production, printing and packaging, plastic processing, and electronic component assembly. Their basic principle is as follows: a high voltage is applied to a discharge needle via a high-voltage power supply, ionizing the air using the corona discharge effect to generate an ionized gas flow containing positive and negative ions. This gas flow is then delivered to the surface of the material to be statically eliminated, where the positive and negative ions in the ionized gas flow neutralize the static charge on the material surface, thus achieving the purpose of eliminating static electricity.

[0003] Currently, some static eliminators on the market integrate sensor detection functions, enabling them to acquire electrostatic potential information of the target object's surface. For example, some products use an ion balance collection grid installed at the outlet of the discharge needle to detect the current flowing through the grounded electrode and perform feedback control on the negative high-voltage power supply to bring the current closer to the target value, thereby controlling long-term ion balance. Other products use sensing rods to measure the electrostatic charge data on the material surface and control the output of the ion generator accordingly.

[0004] However, the aforementioned existing technical solutions still have the following technical defects and shortcomings in terms of parameter adjustment methods:

[0005] First, the control process relies on human experience. The on-site parameter adjustment of existing electrostatic eliminators, especially the initial installation and commissioning and readjustment after changes in operating conditions, mainly depends on the subjective judgment of on-site maintenance personnel. An initial parameter value is set, and adjustments are made based on experience using information from sensors until the electrostatic control result reaches an acceptable range. When the equipment installation location changes, the type of material to be electrostaticated changes, or the temperature and humidity of the workshop environment change, the already adjusted parameters often need to be repeatedly tested and adjusted by experienced personnel. The equipment lacks the ability to autonomously sense changes in operating conditions and automatically adapt parameters.

[0006] Secondly, the control dimensions are isolated. Existing control schemes adjust airflow based on the spatial distance between the electrostatic eliminator and the production line, and adjust ionization parameters based on the actual effect of electrostatic elimination. There is a lack of a coherent coupling mechanism between these two approaches. However, in actual physical processes, the airflow acts as an ion carrier, and changes in its actual state directly affect the ion transport efficiency in the air, thus altering the state of the ions reaching the target substance. Furthermore, changes in ion density due to changes in ionization parameters require adaptation to different airflow velocities for effective transport. Treating these two aspects separately makes it difficult to achieve optimal control efficiency and electrostatic elimination effects at the overall level. Summary of the Invention

[0007] The purpose of this application is to overcome the shortcomings of the prior art and provide an adaptive multi-level control method, system and product for an electrostatic eliminator. This method enables the electrostatic eliminator to adaptively and hierarchically adjust the ionization state parameters and working airflow state parameters according to the deviation of the actual residual electrostatic potential on the material surface without human intervention. This improves the consistency and reliability of the electrostatic elimination effect while taking into account both the control speed and control accuracy.

[0008] Firstly, this application provides an adaptive multi-level control method for an electrostatic eliminator, the technical solution of which includes the following steps:

[0009] S100, Configure the initial operating state parameters of the electrostatic eliminator, including ionization state parameters and operating airflow state parameters;

[0010] S200: After the static eliminator performs static removal operation on the material to be statically removed, it acquires the electrostatic state parameters of the surface of the material to be statically removed, including electrostatic potential and potential polarity.

[0011] S300: Compare the electrostatic potential with the preset potential threshold. If the absolute value of the electrostatic potential is less than or equal to the preset potential threshold, maintain the current working state parameters. If the absolute value of the electrostatic potential is greater than the preset potential threshold, execute S400.

[0012] S400, the control level is determined based on the degree of deviation between the absolute value of the electrostatic potential and the preset potential threshold, and the ionization state parameters and / or working airflow state parameters of the electrostatic eliminator are respectively controlled in stages according to the control level and the potential polarity, corresponding to the control level.

[0013] S500: Perform static removal operation on the material to be statically removed using the adjusted ionization state parameters and working airflow state parameters, reacquire the electrostatic potential and potential polarity of the surface of the material to be statically removed, and return to repeat S300 until the absolute value of the electrostatic potential is less than or equal to the preset potential threshold.

[0014] By adopting the above technical solution, this application uses the deviation between the actual residual electrostatic potential on the material surface and the preset threshold as the basis for regulation. The regulation level is determined based on the deviation, and the regulation direction is determined based on the potential polarity. The ionization state parameters and working airflow state parameters are regulated in stages. Iterative approximation is achieved through closed-loop feedback, so that the regulation process forms an iterative cycle until the residual electrostatic potential reaches the standard, thus ensuring the reliability and consistency of the electrostatic elimination results.

[0015] Preferably, in S400, the method of graded control specifically includes:

[0016] The ionization state parameters and working gas flow state parameters are controlled as a control range formed by several basic control steps. The control amount of the ionization state parameters and working gas flow state parameters is determined by the number of executions of the basic control steps.

[0017] The control levels include at least a first control level where the absolute value of the electrostatic potential deviates relatively small from a preset potential threshold, and a second control level where the absolute value of the electrostatic potential deviates relatively large from a preset potential threshold.

[0018] The number of basic control steps executed at the second control level is greater than the number of basic control steps executed at the first control level.

[0019] By adopting the above technical solution, this application defines the control quantity as the number of executions of the basic control step size. The number of executions of the basic control step size of the second control level, which deviates significantly from the preset potential threshold, is greater than the number of executions of the first control level. This allows the hierarchical control to be quantified in the form of integer multiples of the basic step size, making the control logic clear and easy to implement in engineering. At the same time, since the change of the control quantity is a discrete and controllable step change, it avoids the system oscillation that may be introduced by continuous adjustment and improves the stability of the control process.

[0020] Preferably, the control range of the ionization state parameter includes one or a combination of the potential range of positive and negative high voltage, the duty cycle range of positive and negative high voltage, and the operating frequency of positive and negative high voltage.

[0021] The control range of the working airflow state parameters is the throttle valve opening range for controlling the working airflow velocity or airflow flow rate per unit time.

[0022] By adopting the above technical solution, the control range of ionization state parameters and working gas flow state parameters was determined. The control object was specified as the key physical quantity that directly affects the ion generation concentration, ratio and transport efficiency in the electrostatic eliminator. This allows the solution to clearly define the control object and adjustment range at the engineering level, thus ensuring the feasibility of the technical solution.

[0023] As a preferred option, the regulation of the working airflow state parameters also includes:

[0024] The temperature and humidity of the work site are monitored to obtain environmental state parameters, and the basic control step size of the working airflow state parameters is compensated based on the environmental state parameters.

[0025] By adopting the above technical solution, this application further introduces an environmental temperature and humidity monitoring and compensation mechanism, which can eliminate the interference of environmental changes on the control effect, and enable the graded control to maintain a stable and consistent control response under different seasons and different workshop environmental conditions, thereby improving the working condition adaptability and control robustness of this solution.

[0026] Preferably, multiple static eliminators are connected in series to form a cascaded architecture, and perform static removal operations on the material to be statically removed in sequence; after any one of the static eliminators performs the static removal operation, it independently executes the control steps S200 to S500, and the input of the working state parameters of any later static eliminator is the graded control output of the working state parameters of the previous stage.

[0027] By adopting the above technical solution, each electrostatic eliminator can perform progressive electrostatic elimination on the same material in stages. The starting point of the subsequent stage is the ending point of the previous stage, thereby achieving a deep electrostatic elimination regulation effect that approaches zero potential step by step, making up for the shortcomings of single-stage regulation in terms of physical limits and improving the regulation accuracy.

[0028] Preferably, when the ionization state parameters and working airflow state parameters reach the upper or lower limit of the control range, and the absolute value of the electrostatic potential is greater than the preset potential threshold, S600 is executed to send an alarm signal to the operation and maintenance personnel and prompt manual intervention.

[0029] By adopting the above technical solutions, the control boundaries of the control strategy can be clearly defined, avoiding energy waste and potential safety risks caused by the system's infinite loop adjustment under abnormal conditions, and improving the system's maintainability and engineering practicality.

[0030] Preferably, S400 also includes obtaining the actual operating current of the static eliminator, comparing the actual operating current with the theoretical operating current calculated based on the ionization state parameters, and if the actual operating current is lower than the theoretical operating current and deviates by more than a threshold, then performing a pulse action of the maximum operating airflow state parameters.

[0031] By adopting the above technical solution, this application further introduces a pulse purging mechanism based on actual working current monitoring. By identifying the erosion or contamination state of the discharge needle, a pulse action is executed based on the maximum working airflow state parameter. The impact force of the instantaneous maximum airflow is used to remove the deposits on the surface of the discharge needle, giving the electrostatic eliminator autonomous maintenance capability. Ionization efficiency can be restored without manual disassembly and cleaning, thus extending the continuous operation time of the equipment.

[0032] Secondly, this application provides an adaptive multi-level control system for an electrostatic eliminator, which adopts the following technical solution, including an electrostatic eliminator module, a material electrostatic monitoring and feedback module, and a control module;

[0033] The electrostatic eliminator module includes an ionization component and an airflow component. The ionization component is used to discharge to generate an ionized airflow, and the airflow component is used to drive the ionized airflow toward the material to be extinguished. The ionization component is equipped with an ionization state parameter adjustment interface, and the airflow component is equipped with an electrically controlled throttle valve.

[0034] The material electrostatic monitoring feedback module is located downstream of the electrostatic elimination operation of the material to be eliminated, and is used to obtain the electrostatic state parameters of the surface of the material to be eliminated, including electrostatic potential and potential polarity.

[0035] The control module is connected to the material electrostatic monitoring feedback module, the ionization state parameter adjustment interface, and the electronically controlled throttle valve signal, and is configured to execute the electrostatic eliminator adaptive multi-level control method as described in any one of claims 1 to 7, and to perform graded control of the ionization state parameter and / or the working airflow state parameter.

[0036] Preferably, the static eliminator module consists of several static eliminator units connected in series to form a cascaded architecture. Each static eliminator unit is configured with a corresponding material static monitoring feedback module. The input of the control module to any operating state parameter of the static eliminator unit in the later stage is a graded control output of the operating state parameter of the static eliminator unit in the previous stage.

[0037] Thirdly, this application provides a computer program product, which includes a computer program or instructions, and when the computer program or instructions are executed, they can implement the steps in the above-described adaptive multi-level control method for static eliminators.

[0038] In summary, this application includes at least one of the following beneficial technical effects:

[0039] 1. This application achieves adaptive closed-loop control of the operating parameters of the electrostatic eliminator. The actual electrostatic potential and polarity of the material surface to be eliminated are directly acquired through the material electrostatic monitoring feedback module. The control module automatically completes a closed-loop control process of detection, comparison, graded control, and cyclic feedback. This eliminates reliance on the subjective experience and repeated trial and error of on-site maintenance personnel, significantly reducing the technical threshold for equipment deployment and maintenance, ensuring the consistency and repeatability of the electrostatic elimination effect, and improving the equipment's adaptability under various on-site environmental conditions.

[0040] 2. This application balances rapid convergence and fine-tuning through a tiered control mechanism. It uses the number of basic control steps as the unit of measurement for the control amount, employing a tiered control strategy where the larger the deviation, the larger the control amount and the greater the number of basic control steps. Large control amounts are used to achieve rapid approximation when the deviation is large, while small control amounts are used to achieve fine convergence when the deviation is small, thus differentiating the substantive content of the control through different control strategies.

[0041] 3. This application achieves coordinated control of ionization parameters and airflow parameters. The control levels of ionization state parameters and working airflow state parameters are determined based on the same degree of deviation, exhibiting an inherent correlation. At lower control levels, ionization parameter control takes priority, while at higher control levels, airflow parameter control takes priority. By constructing a coordinated control mechanism, this effectively prevents any single parameter from prematurely entering the diminishing marginal utility range, improving overall control efficiency and reducing unnecessary energy consumption.

[0042] 4. This application achieves multi-stage progressive deep static elimination through a cascaded architecture. Multiple static eliminator units are connected in series to form a cascaded architecture. The input state of the next stage is the graded control output of the previous stage, realizing progressive control that approaches zero potential step by step. It is suitable for the deep static elimination needs of high-speed production lines or fine static treatment. Attached Figure Description

[0043] Figure 1 This is a flowchart illustrating an adaptive multi-level control method for an electrostatic eliminator in an embodiment of this application.

[0044] Figure 2 This is a schematic diagram of the architecture of an adaptive multi-level control system for an electrostatic eliminator in an embodiment of this application;

[0045] Figure 3 This is a schematic diagram of the structure of an electrostatic eliminator ionization component 110 and an airflow component 120 in an embodiment of this application;

[0046] Figure 4 This is a schematic diagram of the architecture of a cascaded electrostatic eliminator adaptive multi-stage control system in an embodiment of this application. Detailed Implementation

[0047] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of this application.

[0048] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. It should be noted that in the optional embodiments of this application, the object information and other related data involved require the permission or consent of the object when the embodiments of this application are applied to specific products or technologies, and the collection, use, and processing of related data must comply with the relevant laws, regulations, and standards of the relevant countries and regions. That is to say, if the embodiments of this application involve data related to the object, it needs to be obtained with the authorization and consent of the object, the authorization and consent of the relevant departments, and in compliance with the relevant laws, regulations, and standards of the country and region. If personal information is involved in the embodiments, the acquisition of all personal information requires the consent of the individual. If sensitive information is involved, the separate consent of the information subject is required, and the embodiments also need to be implemented with the authorization and consent of the object.

[0049] In addition, the term "and / or" in this article is merely a description of the relationship between related objects, indicating that there can be three kinds of relationships. For example, A and / or B can represent three situations: A exists alone, A and B exist simultaneously, and B exists alone.

[0050] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0051] Example 1:

[0052] Please see Figure 1 This embodiment provides an adaptive multi-level control method for an electrostatic eliminator, which automatically completes a closed-loop control process of detection, comparison, graded control, and cyclic feedback to achieve adaptive closed-loop control of the electrostatic eliminator's operating state parameters. Specifically, it includes the following steps.

[0053] S100 configures the initial operating parameters of the electrostatic eliminator, including ionization parameters and operating airflow parameters.

[0054] The configuration of initial operating parameters is the starting point for closed-loop control. Ionization state parameters refer to parameters affecting the generation of positive and negative ions through corona discharge of the discharge needle, such as one or more of the positive and negative high voltage amplitudes, the duty cycles of the positive and negative high voltages, and the ion output frequency. Operating gas flow state parameters refer to parameters affecting the delivery of the ionized gas flow to the material to be electrolyzed, such as the flow rate and / or flow rate per unit time of the ionized gas flow. There are several ways to configure the initial parameters: In one implementation, the system presets a set of default parameter values, such as setting the positive high voltage amplitude to +5kV, the negative high voltage amplitude to -5kV, the duty cycle to 50%, the operating frequency to 10Hz, and the throttle valve opening to 50%, allowing maintenance personnel to start the equipment without manual intervention. In another implementation, maintenance personnel can input a set of empirical initial parameter values ​​through the host computer interface or equipment panel based on site conditions, such as the material type of the material to be electrolyzed, the production line speed, and the installation distance from the electrostatic eliminator to the material surface.

[0055] S200, after the static eliminator performs static removal operation on the material to be statically removed, acquires the electrostatic state parameters of the surface of the material to be statically removed, including electrostatic potential and potential polarity.

[0056] The electrostatic eliminator operates with the initial operating parameters configured in S100 or the parameters after subsequent adjustments. It generates an ionized airflow containing positive and negative ions through corona discharge and blows this airflow onto the surface of the material to be neutralized. The positive and negative ions neutralize the static charge on the material surface. Afterward, the electrostatic state parameters of the material surface are acquired. A non-contact electrostatic potential sensor, such as a field mill electrometer or a vibrating capacitance electrometer, can be used. Its probe is positioned facing the surface of the material and installed at a predetermined distance downstream of the outlet of the electrostatic eliminator module. This sensor can detect the magnitude of the electrostatic potential on the material surface in real time without contacting the material and simultaneously determine whether the potential polarity is positive or negative. The electrostatic potential value reflects the amount of residual static charge on the material surface, while the potential polarity indicates the type of residual static charge. These two pieces of information together form the basis for subsequent control decisions.

[0057] S300: Compare the electrostatic potential with the preset potential threshold. If the absolute value of the electrostatic potential is less than or equal to the preset potential threshold, maintain the current working state parameters. If the absolute value of the electrostatic potential is greater than the preset potential threshold, execute S400.

[0058] The preset potential threshold is a benchmark value used to determine whether the static electricity elimination effect meets the standard, representing the upper limit of the acceptable residual electrostatic potential on the material surface. The specific value of this threshold can be set according to the electrostatic sensitivity requirements of different application scenarios. For example, in electronic component assembly lines, the preset potential threshold can be set to ±50V; in ordinary plastic film roll production lines, it can be set to ±200V. The comparison and judgment logic is based on the absolute value of the electrostatic potential, because regardless of whether the residual charge is positive or negative, its potential harm to subsequent processes depends on the amount of charge rather than the polarity direction. When the absolute value of the electrostatic potential is less than or equal to the preset potential threshold, it indicates that the current static electricity elimination effect meets the process requirements. The system maintains the current operating parameters unchanged and continues to cycle through the monitoring steps S200 to S300 at certain intervals to maintain continuous monitoring of the material's electrostatic state. When the absolute value of the electrostatic potential is greater than the preset potential threshold, it indicates that the current static electricity elimination effect is insufficient, and it is necessary to enter S400 for parameter adjustment.

[0059] S400 determines the control level based on the degree of deviation between the absolute value of the electrostatic potential and the preset potential threshold, and performs graded control on the ionization state parameters and / or working airflow state parameters of the electrostatic eliminator according to the control level and potential polarity, corresponding to the control level.

[0060] S400 is the core step in achieving graded control in this application. Specifically, the deviation of the absolute value of the electrostatic potential from the preset potential threshold characterizes the gap between the current electrostatic elimination effect and the target effect. The greater the deviation, the greater the control intensity required to compensate for the gap. The control level is a control intensity level divided according to the degree of deviation. Different control levels correspond to different control amounts. The greater the deviation, the higher the control level and the greater the control amount. This graded control strategy enables the system to quickly approach the target with a large control amount when the deviation is large, and to achieve fine convergence with a small control amount when the deviation is small, thus balancing control speed and control accuracy. The potential polarity is used to determine the direction of control: if the potential polarity is positive, it indicates that the material surface is rich in positive charge, and it is necessary to increase the supply of negative ions to neutralize the positive charge. The control direction is to increase the negative high voltage amplitude or increase the negative high voltage duty cycle; if the potential polarity is negative, it indicates that the material surface is rich in negative charge, and it is necessary to increase the supply of positive ions to neutralize the negative charge. The control direction is to increase the positive high voltage amplitude or increase the positive high voltage duty cycle. The objects of graded control include one or two types of ionization state parameters and working gas flow state parameters. One type of parameter can be adjusted alone, or both types of parameters can be adjusted simultaneously, depending on the degree of deviation and the actual application requirements.

[0061] More specifically, in the S400, the graded control method includes: dividing the control of ionization state parameters and working gas flow state parameters into control intervals formed by several basic control step sizes; and determining the control amount of ionization state parameters and working gas flow state parameters by the execution number of the basic control step sizes. The basic control step size is the smallest unit of parameter adjustment. For example, for positive and negative high voltage amplitudes, one basic control step size can be defined as 0.5kV; for duty cycle, one basic control step size can be defined as 5%; for operating frequency, one basic control step size can be defined as 100Hz; and for throttle valve opening, one basic control step size can be defined as 5% opening. The control interval is the adjustable range of parameters formed by multiple basic control step sizes arranged sequentially. The actual control amount of the parameter is equal to the basic control step size multiplied by the execution number, reflecting the deviation of the parameter from the initial operating state parameter after control. This method of discretizing continuous control amounts into step execution numbers makes the control process deterministic and repeatable, facilitating accurate calculation and issuance of control commands by the control module.

[0062] The control levels include at least a first control level where the absolute value of the electrostatic potential deviates relatively small from a preset potential threshold, and a second control level where the absolute value of the electrostatic potential deviates relatively large from the preset potential threshold. The number of execution steps of the basic control step size for the second control level is greater than that for the first control level. The control levels are divided based on the deviation degree ΔV = |Vres| - Vth, where Vres is the currently acquired electrostatic potential and Vth is the preset potential threshold. As an example, when ΔV is in the range of 0V to 100V, it is determined to be the first control level, where the deviation degree is small, and the system performs fine approximation with a small control amount; when ΔV is greater than 100V, it is determined to be the second control level, where the deviation degree is large, and the system performs rapid convergence with a larger control amount. It can be understood that the control level division is not limited to two levels. In another embodiment, a third control level can be further set. For example, when ΔV is greater than 100V but less than 500V, it is determined to be the second control level, and when ΔV is greater than 500V, it is determined to be the third control level, using a larger control amount to deal with severely deviated operating conditions. The number of control levels and the corresponding ΔV interval thresholds for each level can be flexibly configured according to the different requirements of control sensitivity and convergence speed in actual application scenarios.

[0063] After determining the control level L, the number of basic control steps for the ionization state parameter Nion(L) and the number of basic control steps for the working airflow state parameter Nair(L) are determined respectively. Taking three-level control as an example, Nion(1) for the first control level can be 1 and Nair(1) can be 0, that is, only one basic control step is performed for the ionization state parameter adjustment, and no adjustment is performed for the working airflow state parameter, achieving small-scale fine-tuning; Nion(2) for the second control level can be 3 and Nair(2) can be 2, that is, three basic control steps for the ionization state parameter and two basic control steps for the working airflow state parameter are performed, achieving medium-amplitude adjustment; Nion(3) for the third control level can be 5 and Nair(3) can be 4, achieving large-amplitude rapid adjustment. The higher the control level, the larger the number of executions and the larger the control amount, so that when the deviation is large, a large control amount is used to quickly approach the target, and when the deviation is small, a small control amount is used to achieve fine convergence, taking into account both control speed and control accuracy.

[0064] The control range of ionization state parameters includes one or a combination of the potential range of positive and negative high voltages, the duty cycle range of positive and negative high voltages, and the operating frequency of positive and negative high voltages. The potential range of positive and negative high voltages refers to the adjustable range of the amplitude of the positive and negative high voltages applied to the discharge needle. For example, the amplitude of the positive high voltage can be adjusted from +1kV to +10kV, and the amplitude of the negative high voltage can be adjusted from -1kV to -10kV. The duty cycle range of positive and negative high voltages refers to the adjustable range of the proportion of time occupied by the effective level in the output waveform of the high voltage power supply. For example, the duty cycle can be adjusted from 10% to 90%. The higher the duty cycle, the greater the proportion of ionization time per unit time, and the higher the ion concentration produced. The operating frequency range of positive and negative high voltages refers to the frequency adjustment range of the output waveform of the high voltage power supply. For example, the operating frequency can be adjusted from 1Hz to 100Hz. The operating frequency affects the periodicity of ion generation; the spatial distribution and proportion of positive and negative ions differ at different frequencies. In actual control, one type of parameter can be selected for adjustment based on the potential polarity and the degree of deviation, or a combination of multiple types of parameters can be adjusted simultaneously. For example, when the electrostatic potential of the material surface is positive and the deviation is small, the duty cycle of the negative high voltage can be increased to increase the proportion of negative ions generated while keeping the amplitude unchanged; when the deviation is large, the amplitude of the negative high voltage, the duty cycle of the negative high voltage, and the working frequency can be increased simultaneously to increase the supply of negative ions from multiple dimensions.

[0065] The control range of the working airflow state parameters is the throttle valve opening range that controls the working airflow velocity or airflow rate per unit time. The throttle valve opening range refers to the adjustable range of the electrically controlled throttle valve from fully closed to fully open; for example, the opening can be continuously or incrementally adjusted within the range of 0% to 100%. When the throttle valve opening is 0%, the airflow channel is completely closed, and there is no ionized airflow output; when the throttle valve opening is 100%, the airflow channel is fully open, and the ionized airflow is output at maximum velocity and flow rate. During the graded control process, when the deviation is large and a large number of ions need to be rapidly transported to the material surface, the throttle valve opening is increased to improve the airflow velocity and flow rate; when the deviation is small and the process enters the fine approximation stage, the throttle valve opening can be appropriately reduced to decrease the airflow's disturbance to the ion spatial distribution, utilizing electrostatic force to achieve more precise ion neutralization.

[0066] In conventional control, operators often increase ionization voltage or airflow based on experience, which can easily lead to diminishing marginal utility due to nonlinear coupling effects between parameters. That is, increasing the parameters has little effect on electrostatic discharge but significantly increases energy consumption and ozone production. In this application, firstly, the deviation ΔV between the measured electrostatic potential and a preset threshold is used as the sole quantitative basis to objectively classify control levels, eliminating the uncertainty of human experience. Secondly, the control direction is clearly defined for positive / negative polarity, controlling positive charge to increase negative ion supply and avoiding reverse adjustment. Thirdly, a discrete control method of basic control step size × execution quantity is adopted, with different execution quantities corresponding to different levels, ensuring precise matching between control intensity and deviation. Large deviations result in rapid convergence, while small deviations allow for fine-tuning, avoiding potential backlash due to over-adjustment. Simultaneously, ionization and airflow parameters are adjusted in combination as needed, rather than in isolation, preventing diminishing marginal utility of a single parameter, balancing electrostatic discharge efficiency and energy consumption optimization, achieving intelligent adaptive control independent of personal experience. This allows the system to automatically match appropriate control intensity based on the actual deviation, avoiding problems such as overshoot or slow convergence.

[0067] S500: Perform static removal operation on the material to be statically removed using the adjusted ionization state parameters and working airflow state parameters, reacquire the electrostatic potential and potential polarity of the surface of the material to be statically removed, and return to repeat S300 until the absolute value of the electrostatic potential is less than or equal to the preset potential threshold.

[0068] S500 forms a closed-loop feedback loop. After each round of graded regulation in S400, the electrostatic eliminator continues to perform electrostatic removal on the material to be statically removed with updated operating parameters. Then, step S200 is executed again to obtain the adjusted electrostatic state parameters, and then step S300 is entered for threshold comparison. If the absolute value of the electrostatic potential is still greater than the preset potential threshold, step S400 is entered again for the next round of graded regulation. This cycle iterates until the absolute value of the electrostatic potential converges below the preset potential threshold, achieving a satisfactory static removal effect. This cyclic feedback mechanism ensures that the system can continuously adjust parameters according to the actual residual electrostatic state on the material surface, rather than stopping after a one-time adjustment, thus adapting to dynamic operating conditions such as changes in production line speed and material properties. The loop terminates when the absolute value of the electrostatic potential is less than or equal to the preset potential threshold. At this time, the system maintains the current parameters and continues to monitor. Once the electrostatic potential is detected to exceed the limit again, the regulation process is retried to achieve continuous adaptive closed-loop control.

[0069] S600: If the state parameters and working airflow state parameters reach the upper or lower limit of the control range, and the absolute value of the electrostatic potential is greater than the preset potential threshold, an alarm signal will be sent to the operation and maintenance personnel and manual intervention will be prompted.

[0070] The control range for ionization state parameters includes the potential range of positive and negative high voltage, the duty cycle range of positive and negative high voltage, and the operating frequency range of positive and negative high voltage. The control range for working airflow state parameters is the throttle valve opening range. Each control range has a clearly defined upper and lower limit, which define the physical or safety boundaries of parameter adjustment. During normal closed-loop control, the system gradually converges the electrostatic potential to below the preset potential threshold through successive rounds of graded control. The parameters move within the control range but usually do not reach the limit value. However, under certain abnormal operating conditions, the system may still be unable to reduce the electrostatic potential below the threshold after multiple rounds of control, and at the same time, one or more parameters may have reached the upper or lower limit of the control range, making further adjustment in the current direction impossible.

[0071] S600 is an anomaly handling step designed specifically for such boundary conditions. Specifically, after each round of graded control in step S400 is completed, the control module checks the actual values ​​of the ionization state parameters and the working gas flow state parameters after this round of control. If it is found that at least one parameter has reached the upper or lower limit of its corresponding control range—for example, the positive high voltage amplitude has reached the upper limit of +10kV or the negative high voltage amplitude has reached the lower limit of -10kV—and the absolute value of the electrostatic potential detected by the material electrostatic monitoring feedback module is still greater than the preset potential threshold, it indicates that the system has exhausted its parameter adjustment capabilities under the current operating conditions but still cannot achieve a satisfactory electrostatic discharge effect. Continuing automatic control is meaningless, and manual intervention is required to investigate the root cause.

[0072] After triggering step S600, the control module sends an alarm signal to the maintenance personnel. The alarm signal output can take several forms to adapt to different on-site deployment environments and maintenance management modes. In one implementation, the control module drives the audible and visual alarm device on the equipment itself, such as illuminating a red alarm indicator light and triggering a buzzer, enabling on-site inspection personnel to notice abnormal equipment immediately. In another implementation, the control module sends an alarm message to the host computer system via a communication interface. The host computer monitoring software then displays an alarm dialog box showing the alarm content, current parameter status, and electrostatic potential value, facilitating remote monitoring by maintenance personnel in the control room. These alarm methods can be used individually or in combination.

[0073] After an alarm signal is issued, maintenance personnel are prompted to conduct manual inspection. For example, if the discharge needle has burned out or aged, it needs to be cleaned or replaced. Another example is a potential malfunction in the high-voltage power supply unit, where the output voltage fails to reach the set value or the output waveform is distorted, resulting in an actual ionization effect far below expectations; in this case, the high-voltage power supply module needs to be repaired or replaced. Yet another example is potential blockage in the airflow channel or duct; in this case, the duct needs to be cleaned or the throttling valve repaired. Furthermore, extreme changes in the material or movement speed of the material to be statically neutralized may occur beyond the equipment's design range. For instance, a significant increase in production line speed may cause the material to remain in the static elimination area for too short a time, or the electrostatic potential on the material surface may be abnormally high, exceeding the static elimination capacity limit of a single static eliminator; in this case, it is necessary to consider adding cascade units or adjusting the production line process parameters.

[0074] Example 2:

[0075] Based on the closed-loop control process described in Example 1, this embodiment further provides a scheme for progressive control using a cascaded architecture of multiple static eliminators. Multiple static eliminators are connected in series to form a cascaded architecture, sequentially performing static removal operations on the material to be statically removed. After any stage of static eliminator performs static removal, control steps S200 to S500 are executed, and the input of the operating state parameters of any subsequent stage static eliminator becomes the graded control output of the operating state parameters of the previous stage.

[0076] Specifically, multiple static eliminators are arranged sequentially along the movement direction of the material to be static-eliminated on the production line, each capable of independently performing static removal operations. Downstream of the outlet of each static eliminator, the residual electrostatic potential and polarity of the material surface after that stage of static removal treatment are detected. Each stage of static eliminator and its corresponding monitoring sensor are connected to the central control module or host computer via an industrial bus to coordinate parameter transmission and control execution between stages.

[0077] The cascaded architecture's workflow is as follows. The first-stage electrostatic eliminator unit starts operating with initial working state parameters. The configuration method for these initial parameters is consistent with step S100 in Example 1; system default parameters can be used, or they can be input by maintenance personnel based on on-site conditions. After the material to be electrostatically eliminated passes through the first-stage electrostatic eliminator, the closed-loop control process of steps S200 to S400 is executed based on the detected residual electrostatic potential and potential polarity on the material surface, outputting a graded control output for the working state parameters of the first-stage electrostatic eliminator. This output serves as the initial input value for the second-stage electrostatic eliminator unit. The central control module writes the graded control output into the initial parameter register of the second-stage electrostatic eliminator unit. The second-stage electrostatic eliminator unit starts operating with these initial working state parameters and performs electrostatic state detection and graded control again on the surface of the material after electrostatic elimination. This process continues, with the third-stage electrostatic eliminator using the graded control output of the second-stage electrostatic eliminator as the initial input value, further eliminating and controlling electrostatics based on the previous stage.

[0078] The core of this cascaded transmission mechanism lies in the fact that each stage of the electrostatic eliminator does not independently search for optimal parameters from scratch. Instead, it uses the parameters that have already converged or are close to converged in the previous stage as a starting point, and performs more refined electrostatic elimination based on the results of the previous stage. The previous stage bears the main electrostatic elimination load, significantly reducing the electrostatic potential of the material surface from a high initial value; the subsequent stage deals with the already significantly reduced residual potential, and can be finely controlled within a small deviation range. This avoids the problem of needing to repeatedly and significantly adjust parameters due to excessive initial deviations in single-stage electrostatic elimination.

[0079] It is understandable that the number of cascaded stages in a cascaded architecture is not limited to three. Depending on the actual application scenario and the required static elimination depth, it can be set to two, four, or more stages. The spacing between each static eliminator unit can be flexibly adjusted according to the production line layout and material movement speed. The installation position of the corresponding static monitoring feedback sensor for each stage can also be optimized according to detection needs, for example, installed within 10cm to 50cm downstream of the air outlet of the static eliminator unit of that stage. The signal connection between the control module and each static eliminator unit can use communication methods such as RS485 bus, CAN bus, or industrial Ethernet to achieve centralized and coordinated control of each stage of the unit.

[0080] This embodiment achieves multi-stage progressive deep electrostatic elimination through a cascaded architecture. The input state of each subsequent stage becomes the graded control output of the previous stage, allowing each stage to supplement and optimize the electrostatic elimination results of the previous stage, progressively approaching zero potential. This architecture is particularly suitable for deep electrostatic elimination scenarios in high-speed production lines or for materials with high electrostatic charge. When faced with extremely high initial electrostatic potentials or extremely fast production line speeds, single-stage electrostatic eliminators may struggle to reduce the residual potential below the target threshold in a single electrostatic elimination process due to limited control range or insufficient ion transport time. However, the cascaded architecture, through multi-stage relay electrostatic elimination, effectively expands the overall electrostatic elimination capability and control precision of the system.

[0081] Example 3:

[0082] This embodiment, based on the above embodiment, adds monitoring of the ambient temperature and humidity at the work site, obtains environmental state parameters, and compensates for the basic control step size of the working airflow state parameters based on the environmental state parameters.

[0083] Specifically, the system collects temperature and humidity data of the work site in real time through environmental temperature and humidity sensors and sends them to the control module. The environmental compensation unit in the control module then corrects the number of basic adjustment steps for the working airflow state parameters based on this data.

[0084] The compensation logic is based on the physical mechanism of humidity's influence on ion mobility. When air humidity is high, the water molecule content increases. Positive and negative ions generated by ionization are more likely to collide and adsorb with water molecules during their migration to the surface of the material to be neutralized, forming larger hydrated ion clusters. The mobility of these hydrated ion clusters is significantly lower than that of free ions in dry air, resulting in a reduced actual number of ions reaching the material surface at the same airflow velocity and a decreased neutralization reaction efficiency. Conversely, when air humidity is low, ion mobility is higher, and ion transport efficiency is higher under the same airflow conditions. If the airflow parameters are not adaptively compensated, increasing the airflow by the default step size in a high-humidity environment may lead to insufficient actual ion arrival, resulting in a less than expected control effect. The system will then determine that the deviation has not converged and continue to increase the control amount, easily causing overshoot. In a low-humidity environment, excessively high ion transport efficiency may lead to over-neutralization, similarly causing residual potential fluctuations.

[0085] As an example of a compensation strategy, a first humidity threshold and a second humidity threshold can be set. The first humidity threshold corresponds to high humidity conditions, for example, 70% RH; the second humidity threshold corresponds to low humidity conditions, for example, 30% RH. When the ambient humidity is higher than the first humidity threshold, it indicates that the water molecule content in the air is high and the ion mobility is reduced. At this time, the basic control step size of the working airflow state parameters is reduced to compensate, for example, by multiplying Nair(L) determined by the control strategy by a compensation coefficient. The purpose of this is to avoid blindly increasing the airflow under high humidity conditions due to reduced ion transport efficiency, which would lead to energy waste and increased airflow disturbance. When the ambient humidity is lower than the second humidity threshold, it indicates that the air is relatively dry and the ion mobility is high. At this time, Nair(L) is increased to fully utilize the favorable conditions of easy ion transport under dry air and accelerate the dissipation speed. When the ambient humidity is between the second humidity threshold and the first humidity threshold, the original Nair(L) can be kept unchanged, that is, the compensation coefficient is 1.0.

[0086] It is understandable that the specific value of the humidity threshold and the magnitude of the compensation coefficient are not fixed and can be flexibly configured according to the characteristics of the installation environment and the requirements for static eliminator accuracy in the actual application scenario. For example, in workshops with consistently high humidity in the southern coastal areas, the first humidity threshold can be appropriately lowered to 65%RH; in the dry northern regions, the second humidity threshold can be appropriately raised to 35%RH. The compensation coefficient can also adopt a nonlinear functional relationship, such as interpolation calculation based on the empirical curve of humidity and ion mobility, rather than simple piecewise constant compensation. In addition, temperature also has a certain impact on ion mobility. When the temperature rises, the thermal motion of gas molecules intensifies, and the ion diffusion rate accelerates. In another embodiment, temperature data can also be incorporated into the compensation model to construct a temperature-humidity joint compensation function to further improve the compensation accuracy.

[0087] By introducing an environmental temperature and humidity compensation mechanism, the electrostatic eliminator can automatically adapt to the parameter optimization requirements under different seasons and workshop environmental conditions, eliminating the impact of environmental humidity changes on ion mobility, improving the accuracy and convergence speed of graded control, and further enhancing the equipment's adaptability and long-term operational stability in complex industrial environments.

[0088] Example 4:

[0089] Based on the above embodiments, this implementation further provides a pulse purging self-cleaning mechanism based on actual operating current monitoring. During the graded control execution process in step S400, monitoring of the operating current of the static eliminator is further added. The actual operating current of the static eliminator is obtained, and it is compared with the theoretical operating current calculated based on ionization state parameters. If the actual operating current is lower than the theoretical operating current and deviates beyond a threshold, a pulse action is executed based on the maximum operating airflow state parameters.

[0090] Specifically, the actual operating current is obtained by connecting a current sampling circuit in series on the grounding circuit side of the high-voltage power supply unit of the static eliminator. The value of the sampling resistor needs to be selected to balance measurement accuracy and power loss. For example, a precision resistor in the range of 1Ω to 10Ω can be selected so that the voltage drop generated within the normal operating current range can be accurately distinguished by the analog-to-digital converter without significantly affecting the output voltage of the high-voltage power supply.

[0091] The theoretical operating current is calculated based on the current ionization state parameters. During corona discharge, the operating current of the discharge needle has a definite functional relationship with the applied high voltage amplitude, duty cycle, and operating frequency. As an example calculation method, the theoretical operating current Itheory can be expressed as a function of the high voltage amplitude Vpp, duty cycle D, and operating frequency f, i.e., Itheory = k × Vpp × D × f, where k is a proportionality coefficient related to the geometry of the discharge needle, electrode spacing, and air dielectric constant, which can be predetermined through factory calibration or laboratory testing and stored in the non-volatile memory of the control module. For example, in a specific model of electrostatic eliminator, the calibrated k value is 0.02mA / (kV·Hz). When the high voltage amplitude is 5kV, the duty cycle is 50%, and the operating frequency is 10Hz, the theoretical operating current is 0.02×5×0.5×10=0.5mA. In another embodiment, the theoretical operating current can also be obtained by looking up a table. That is, the actual operating current corresponding to different combinations of ionization state parameters is measured in advance under laboratory conditions, and a parameter-current mapping table is established and stored in the control module. During actual operation, the corresponding theoretical operating current value is obtained by directly looking up the table based on the current ionization state parameters.

[0092] When comparing the actual operating current with the theoretical operating current, a deviation threshold is set as the benchmark for determining whether the ionization efficiency has abnormally decreased. The deviation threshold can be set as the percentage by which the actual operating current is lower than the theoretical operating current. For example, when the actual operating current is more than 30% lower than the theoretical operating current, it is determined that the ionization efficiency has abnormally decreased.

[0093] A common cause of decreased ionization efficiency is the accumulation of dust, oil, fiber debris, or ablation-induced impurities on the surface of the discharge needle during long-term operation. These deposits alter the electric field distribution at the needle tip, suppressing the intensity of corona discharge and resulting in a significant reduction in the actual ion concentration generated under the same high voltage amplitude and duty cycle. In this situation, the control module triggers a pulse action, instantaneously opening the electronically controlled throttle valve to its maximum opening, such as 100%, allowing the airflow assembly to output ionizing airflow at maximum flow rate. This continues for a preset time before returning to the original opening value before the pulse action. The preset duration can be set according to the response speed and cleaning effect of the airflow assembly, for example, 2 seconds. Within these 2 seconds, the high-speed pulsed airflow generates a strong impact force on the surface of the discharge needle, blowing away dust, oil, and other contaminants adhering to the surface, restoring the needle to a clean state, and thus restoring its normal corona discharge efficiency. After the pulse action is completed, the control module reacquires the actual working current and compares it with the theoretical working current. If the current has returned to the normal range, the normal step S400 graded control process continues to be executed. If the current is still too low, the pulse action can be executed again, or the alarm will be triggered after the cumulative number of pulse actions exceeds the preset upper limit, prompting manual inspection of whether the discharge needle has suffered irreversible ablation or mechanical damage.

[0094] This embodiment achieves online self-diagnosis of the ionization efficiency of the discharge component by comparing the actual operating current with the theoretical operating current calculated based on the ionization state parameters. When an abnormal decrease in efficiency is detected, a pulse purging self-cleaning action is automatically executed. The impact force of the instantaneous maximum airflow is used to remove the deposits on the surface of the discharge needle, thereby restoring the corona discharge efficiency. This avoids the abnormal situation of continuous deterioration of the static elimination effect and parameter control falling into the limit state caused by discharge needle contamination. It improves the stability and reliability of the static eliminator under long-term continuous operation conditions and reduces the frequency and cost of manual shutdown for cleaning and maintenance.

[0095] Example 5:

[0096] Please see Figure 2 This embodiment provides an adaptive multi-level control system for an electrostatic eliminator, which includes an electrostatic eliminator module 100, a material electrostatic monitoring and feedback module 200, and a control module 300.

[0097] The static eliminator module 100 includes an ionization component 110 and an airflow component 120. The ionization component 110 is used to discharge to generate an ionized airflow, and the airflow component 120 is used to drive the ionized airflow toward the material to be extinguished. The ionization component is equipped with an ionization state parameter adjustment interface, and the airflow component is equipped with an electrically controlled throttle valve.

[0098] Specifically, please refer to Figure 3The ionization component 110 is the core component for generating positive and negative ions, and it includes a discharge needle 111, a grounding electrode 112, and a high-voltage power supply unit 113. The high-voltage power supply unit is configured to apply positive and / or negative high voltage to the discharge needle 111, and to place the grounding electrode 112 on the side of the discharge needle 111. Through corona discharge, air molecules near the discharge needle 111 are ionized, generating an ionized gas flow containing positive and negative ions. The high-voltage power supply unit 113 internally includes a high-voltage transformer, a rectifier and filter circuit, and a pulse width modulation control circuit, capable of precisely adjusting the amplitude, duty cycle, and operating frequency of the output voltage according to control commands. The ionization state parameter adjustment interface is the signal channel between the ionization component and the control module, used to receive control commands from the control module 300 and convert the commands into electrical signals executable by the high-voltage power supply unit 113. The grounding electrode 112 is also connected to a current sampling circuit 114 to sample the actual operating current of the ionization component 110 and verify it against the theoretical operating current.

[0099] The airflow assembly 120 is used to directionally deliver the ionized airflow generated by the ionization assembly to the surface of the material to be neutralized. In an embodiment of this application, the airflow assembly 120 is composed of a compressed air pipeline, including a plurality of jet ports 121 arranged circumferentially around the discharge needle 111 and an electrically controlled throttle valve 122. The opening degree of the electrically controlled throttle valve 122 is driven by a stepper motor or a proportional electromagnet, and the flow rate and volume of the airflow are directly controlled by adjusting the opening degree of the electrically controlled throttle valve 122. The opening degree of the electrically controlled throttle valve can be continuously adjusted within the range of 0% to 100%, with 0% corresponding to a completely closed state and 100% corresponding to a completely open state. The control module 300 controls the opening degree of the electrically controlled throttle valve 122 by outputting a pulse width modulation signal or an analog voltage signal, thereby achieving precise adjustment of the working airflow state parameters through the jet ports 121.

[0100] The material electrostatic monitoring feedback module 200 is located downstream of the electrostatic elimination process of the material to be eliminated. It is used to acquire the electrostatic state parameters of the material's surface, including electrostatic potential and polarity. The module employs a non-contact electrostatic potential sensor, such as a field mill electrometer or a vibration capacitance electrometer. The sensors do not require direct contact with the material surface, enabling real-time online monitoring without affecting material movement or damaging the surface. The sensor probe faces the surface of the material to be eliminated and is installed at a preset distance downstream of the outlet of the electrostatic eliminator module. This preset distance is determined based on factors such as the outlet size, airflow diffusion angle, and material movement speed, and is typically set within a range of 10cm to 50cm downstream of the outlet to ensure that the detected electrostatic potential accurately reflects the residual charge state of the material surface after the elimination process.

[0101] The control module is connected to the material electrostatic monitoring feedback module, the ionization state parameter adjustment interface, and the electronically controlled throttle valve signal, serving as the decision-making and control center of the entire system. In one implementation, the control module is an embedded microcontroller integrating an analog-to-digital converter, a digital-to-analog converter, a pulse width modulation output channel, and multiple communication interfaces, meeting the electrostatic eliminator's needs for signal acquisition, parameter adjustment, and communication. In another implementation, the control module is a programmable logic controller (PLC), suitable for scenarios in industrial automation production lines requiring integration with a PLC control system. The PLC implements the control logic through ladder diagrams or structured text programming and communicates with sensors and actuators via an industrial fieldbus. In yet another implementation, the control module is an industrial computer, such as an embedded industrial PC based on the x86 architecture, running a real-time operating system or a general-purpose operating system. It possesses stronger data processing capabilities and human-machine interaction capabilities, suitable for applications requiring complex data analysis, remote monitoring, and centralized management.

[0102] The control module is also equipped with a communication interface for data interaction with the host computer system, enabling remote monitoring and parameter configuration. The communication interface can use industrial communication protocols such as RS485 bus, CAN bus, or industrial Ethernet. The control module periodically sends information such as current operating status parameters, electrostatic potential values, control levels, and alarm status to the host computer. Maintenance personnel can view the equipment's operating status in real time through the host computer monitoring software and remotely modify configuration parameters such as preset potential thresholds, control level division thresholds, and basic control step sizes.

[0103] Please see Figure 4 Based on the aforementioned system hardware architecture, in another implementation, an adaptive multi-level control system for electrostatic eliminators based on a cascaded architecture can also be adopted. The electrostatic eliminator module 100 consists of several electrostatic eliminator units 101 connected in series to form a cascaded architecture. Each electrostatic eliminator unit 101 is equipped with a material electrostatic monitoring feedback module 200. The control module 300 takes the operating state parameters of any subsequent electrostatic eliminator unit 101 as input and outputs the hierarchical control of the operating state parameters of the preceding electrostatic eliminator unit 101.

[0104] Specifically, multiple static eliminator units 101 are arranged sequentially along the movement direction of the material to be statically eliminated, forming a spatial series structure. Each static eliminator unit is an independent functional entity, containing its own ionization component and airflow component, capable of independently performing the complete static elimination action of generating ionized airflow through corona discharge and blowing the ionized airflow onto the material surface. The spacing between each static eliminator unit is determined according to the actual spatial layout of the production line and the material movement speed. For example, in a plastic film roll production line, the spacing between two adjacent static eliminator units can be set to 30cm to 100cm to ensure that the material has sufficient transition space after the previous static elimination treatment and before entering the next static elimination area, allowing the residual static potential to stabilize, and also providing a suitable detection position for the corresponding material static monitoring feedback module.

[0105] Each static eliminator unit has a corresponding material static electricity monitoring and feedback module 200 downstream of its air outlet. Each module independently detects the residual static potential and polarity of the material surface after its static electricity elimination treatment and sends the data to the control module 300. This architecture, with each unit having its own independent feedback module, allows the control module to obtain precise data on the static electricity elimination effect at each stage, enabling it to develop targeted control strategies for each static eliminator unit, rather than relying on a single end feedback signal for general overall adjustment.

[0106] The control module 300 is connected to all static eliminator units 101 and all material static monitoring feedback modules 200 via a communication bus. In one embodiment, the communication bus uses an RS485 bus, with the control module 300 acting as the bus master and each static eliminator unit 101 and material static monitoring feedback module 200 acting as slaves, exchanging data via the Modbus RTU protocol. The RS485 bus has advantages such as strong anti-interference capability, long transmission distance, and support for multiple nodes, making it suitable for applications with a wide distribution of equipment in industrial production lines. Regardless of the communication method used, the control module 300 can send parameter configuration commands and control commands to each static eliminator unit 101 via the bus and receive static status data uploaded by each material static monitoring feedback module 200.

[0107] The input configuration logic of the control module 300 for the operating status parameters of the subsequent stage electrostatic eliminator unit is the core of the cascade architecture. Internally, the control module 300 allocates an independent parameter register area for each stage electrostatic eliminator unit 101 to store the current operating status parameters of that stage. After the i-th stage electrostatic eliminator unit completes one round of graded regulation, the control module reads the graded regulation output of the i-th stage from the parameter register of the i-th stage and then writes it into the initial parameter register of the (i+1)-th stage as the initial value for the (i+1)-th stage electrostatic eliminator unit to start working. This parameter transfer process is automatically completed by the control module without manual intervention.

[0108] This parameter transfer mechanism means that the static eliminator unit 101 does not independently search for optimal parameters from scratch, but rather uses the parameters of the previous stage that have already converged or are close to converged as a starting point, and performs more refined supplementary static elimination based on the static elimination results of the previous stage. From a hardware implementation perspective, the control module 300 can complete the parameter transfer between stages through read and write operations of the parameter registers, without the need for additional hardware circuits or analog signal transmission links, making the implementation simple and reliable. At the same time, since the parameter registers of each stage are independent within the control module, the control module can independently record and track the control process of each stage, facilitating subsequent data analysis and fault diagnosis.

[0109] Example 6:

[0110] This embodiment provides a computer program product, which includes a computer program or instructions. When the computer program or instructions are executed, they can implement the steps in the above-described adaptive multi-level control method for static eliminators.

[0111] The specific implementation of a computer program product can take many forms. In one embodiment, the computer program product is a non-volatile readable storage medium built into the control module. This non-volatile readable storage medium can be an electrically erasable programmable read-only memory (EEPROM), Flash memory, ferroelectric memory (FRAM), or other semiconductor storage devices capable of retaining their stored contents after power failure. When the processor of the control module powers on, it loads and executes the firmware program from the non-volatile readable storage medium. The processor, according to the instruction sequence in the firmware program, sequentially executes steps such as initial operating state parameter configuration, electrostatic state parameter acquisition, threshold comparison and determination, deviation degree calculation and control level determination, graded control execution, and cyclic feedback. Thus, without the need for external software installation, the electrostatic eliminator possesses complete adaptive multi-level control functions. The advantage of this built-in firmware form is that the device is ready to use immediately, and users do not need to perform any software installation or configuration operations, reducing the technical threshold for device deployment.

[0112] In another implementation, the computer program product is a downloadable software application. This software application can be a host computer control software provided as a standalone installation package, running on an industrial computer or embedded industrial control computer that communicates with the static eliminator. It sends control commands to the static eliminator's control module via a communication interface and receives feedback data, enabling remote adaptive control of the static eliminator. Users can download the latest firmware upgrade package from a server provided by the equipment manufacturer or service provider via the network. Then, using host computer software, a dedicated programming tool, or the device's built-in firmware upgrade interface, they can write the computer program instructions from the upgrade package into the control module's non-volatile readable storage medium, replacing or updating the original firmware program.

[0113] It is understood that the delivery form of computer program products is not limited to the two mentioned above. Regardless of the specific form adopted, as long as the computer program or instructions can implement the steps in the adaptive multi-level control method for electrostatic eliminator described in this application when executed by the processor, they are all within the scope of this embodiment.

[0114] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. An adaptive multi-stage control method for an electrostatic eliminator, characterized in that, Includes the following steps: S100, Configure the initial operating state parameters of the electrostatic eliminator, including ionization state parameters and operating airflow state parameters; S200: After the static eliminator performs static removal operation on the material to be statically removed, it acquires the electrostatic state parameters of the surface of the material to be statically removed, including electrostatic potential and potential polarity. S300: Compare the electrostatic potential with the preset potential threshold. If the absolute value of the electrostatic potential is less than or equal to the preset potential threshold, maintain the current working state parameters. If the absolute value of the electrostatic potential is greater than the preset potential threshold, then execute S400; S400, the control level is determined based on the degree of deviation between the absolute value of the electrostatic potential and the preset potential threshold, and the ionization state parameters and / or working airflow state parameters of the electrostatic eliminator are respectively controlled in stages according to the control level and the potential polarity, corresponding to the control level. S500: Perform static removal operation on the material to be statically removed using the adjusted ionization state parameters and working airflow state parameters, reacquire the electrostatic potential and potential polarity of the surface of the material to be statically removed, and return to repeat S300 until the absolute value of the electrostatic potential is less than or equal to the preset potential threshold.

2. The adaptive multi-level control method for an electrostatic eliminator according to claim 1, characterized in that, In S400, the method of graded regulation specifically includes: The ionization state parameters and working gas flow state parameters are controlled as a control range formed by several basic control steps. The control amount of the ionization state parameters and working gas flow state parameters is determined by the number of executions of the basic control steps. The control levels include at least a first control level where the absolute value of the electrostatic potential deviates relatively small from a preset potential threshold, and a second control level where the absolute value of the electrostatic potential deviates relatively large from a preset potential threshold. The number of basic control steps executed at the second control level is greater than the number of basic control steps executed at the first control level.

3. The adaptive multi-level control method for an electrostatic eliminator according to claim 2, characterized in that, The control range of the ionization state parameters includes one or a combination of the potential range of positive and negative high voltage, the duty cycle range of positive and negative high voltage, and the operating frequency of positive and negative high voltage. The control range of the working airflow state parameters is the throttle valve opening range for controlling the working airflow velocity or airflow flow rate per unit time.

4. The adaptive multi-level control method for an electrostatic eliminator according to claim 3, characterized in that, The regulation of working airflow state parameters also includes: The temperature and humidity of the work site are monitored to obtain environmental state parameters, and the basic control step size of the working airflow state parameters is compensated based on the environmental state parameters.

5. The adaptive multi-level control method for an electrostatic eliminator according to claim 1, characterized in that, Multiple static eliminators are connected in series to form a cascaded architecture, and perform static removal operations on the material to be statically removed in sequence. After any static eliminator performs static removal operations, it independently executes the control steps S200 to S500. The input of the working state parameters of any static eliminator in the next stage is the graded control output of the working state parameters of the previous stage.

6. The adaptive multi-level control method for an electrostatic eliminator according to claim 2, characterized in that, When the ionization state parameters and working airflow state parameters reach the upper or lower limit of the control range, and the absolute value of the electrostatic potential is greater than the preset potential threshold, S600 is executed to send an alarm signal to the operation and maintenance personnel and prompt manual intervention.

7. The adaptive multi-level control method for an electrostatic eliminator according to claim 1, characterized in that, S400 also includes acquiring the actual operating current of the static eliminator, comparing the actual operating current with the theoretical operating current calculated based on the ionization state parameters, and if the actual operating current is lower than the theoretical operating current and deviates by more than a threshold, then performing a pulse action on the maximum operating airflow state parameters.

8. An adaptive multi-stage control system for an electrostatic eliminator, characterized in that, It includes an electrostatic eliminator module, a material electrostatic monitoring and feedback module, and a control module; The electrostatic eliminator module includes an ionization component and an airflow component. The ionization component is used to discharge to generate an ionized airflow, and the airflow component is used to drive the ionized airflow toward the material to be extinguished. The ionization component is equipped with an ionization state parameter adjustment interface, and the airflow component is equipped with an electrically controlled throttle valve. The material electrostatic monitoring feedback module is located downstream of the electrostatic elimination operation of the material to be eliminated, and is used to obtain the electrostatic state parameters of the surface of the material to be eliminated, including electrostatic potential and potential polarity. The control module is connected to the material electrostatic monitoring feedback module, the ionization state parameter adjustment interface, and the electronically controlled throttle valve signal, and is configured to execute the electrostatic eliminator adaptive multi-level control method as described in any one of claims 1 to 7, and to perform graded control of the ionization state parameter and / or the working airflow state parameter.

9. The adaptive multi-stage control system for an electrostatic eliminator according to claim 8, characterized in that, The static eliminator module consists of several static eliminator units connected in series to form a cascaded architecture. Each static eliminator unit is configured with a corresponding material static monitoring feedback module. The input of the control module to any operating state parameter of the static eliminator unit in the later stage is a graded control output of the operating state parameter of the static eliminator unit in the previous stage.

10. A computer program product, characterized in that, The computer program product includes a computer program or instructions that, when executed, can perform the steps of the adaptive multi-level control method for the electrostatic eliminator as described in any one of claims 1 to 7.

Images