A monitoring and early warning system for a folding box house production device

Abstract

This invention discloses a monitoring and early warning system for foldable container house production equipment, relating to the field of monitoring and early warning technology. During trial folding, the system identifies folding events such as side wall panel rotation, pulley entry into groove, support wheel contact with groove, diagonal brace folding, and locking point approach. It determines the sequence deviation by combining angle, stroke, force, load, and acoustic vibration, and compares this with qualified records of the same model and process. When at least two of the following are consecutively correlated: hinge lag, pulley / support wheel premature force application, and locking point premature contact, a corresponding early warning is output. This invention uses side wall panel rotation, pulley entry into groove, support wheel contact with groove, diagonal brace folding, and locking point approach as folding events, determining the folding sequence deviation through the sequence of events. Compared to current, pressure, or position signal alarms, this system can detect hinge, slide, sealing strip, or locking seat abnormalities before the load exceeds the limit, reducing the risk of hinge damage, slide deformation, and sealing strip crushing.

Description

Technical Field

[0001] This invention relates to the field of monitoring and early warning technology, and in particular to a monitoring and early warning system for foldable container house production equipment. Background Technology

[0002] Foldable container houses typically consist of a base frame, top frame, side wall panels, end wall panels, hinge assemblies, sliding tracks, pulleys, support wheels, diagonal braces, and locking components. After production, they undergo unfolding, folding, locking, and packaging processes to facilitate rapid deployment at the construction site. For mass-production applications such as export aid camps, emergency isolation camps, and temporary dormitory complexes, foldable container houses often require trial folding before leaving the factory to ensure a smooth transition from the unfolded state to the packaged transport state.

[0003] In existing production processes, the trial folding station typically relies on manual observation, drive motor current, hydraulic pressure, limit switches, or single-position sensors to determine whether the folding is in place. The equipment only stops or alarms when the folding mechanism experiences significant jamming, increased load, or locking failure. While this method can identify more serious motion anomalies, it struggles to detect early abnormalities during the folding process.

[0004] Specifically, the production of folding container houses is affected by factors such as welding deformation, coating thickness, sealing strip assembly height, hinge pin coaxiality, slide groove opening width, and lock seat installation position. These factors may not immediately cause a single parameter to exceed its limit, but they can alter the sequence of events: side wall panel rotation, pulley entry into the slide groove, support wheel contact with the slide groove edge, diagonal brace retraction, and locking point approach. For example, if hinge rotation is delayed, subsequent locking points may be stressed prematurely; if the slide groove spacing is too small, pulleys or support wheels may prematurely compress the slide groove before the wall panel reaches the predetermined angle; if the sealing strip compression is too large, the locking points may experience abnormal contact before reaching the normal locking posture.

[0005] Existing monitoring methods focus primarily on whether the folding is complete or whether the drive load exceeds limits, without identifying the sequential relationship between multiple folding events. This leads to early assembly deviations being easily overlooked. By the time the drive load increases significantly or locking fails, hinges, pulleys, tracks, sealing strips, or locking points may have already been damaged, deformed, or abnormally worn. This not only affects the quality of the container house at the factory but also increases rework time and the risk of production line stoppages. Therefore, we propose a monitoring and early warning system for folding container house production equipment. Summary of the Invention

[0006] The purpose of this invention is to provide a monitoring and early warning system for foldable container house production equipment to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a monitoring and early warning method for foldable container house production equipment, comprising:

[0008] When the test folding mechanism drives the container to be tested to move from the unfolded state to the packed state, the rotation of the side wall panel, the entry of the pulley into the slide groove, the support wheel abutting the edge of the slide groove, the folding of the diagonal brace and the approach of the locking point are successively determined as folding events.

[0009] Based on the angular position, travel position, locking point force, driving load and acoustic vibration signal corresponding to each folding event, determine the current folding sequence offset of the container house;

[0010] The folding sequence offset is compared with the folding sequence of qualified container houses of the same model under the same prior process history. When at least two of the following are continuously associated: hinge rotation lag, pulley or support wheel being stressed in advance, and locking point contacting in advance, it is determined that there is a risk of folding jamming, and warning information corresponding to hinge coaxiality, slide groove spacing or sealing strip compression is output.

[0011] Preferably, determining the folding order offset includes:

[0012] First, select records from the trial folding records of qualified container houses that have the same container size, folding direction, hinge specifications and locking point arrangement as the current container house to form a basic reference record;

[0013] Then, based on the current welding cooling time, spraying thickness grade, sealing strip assembly batch, and hinge pin batch of the container house, select the corresponding process reference record from the basic reference record to avoid misjudging the normal resistance difference caused by different preceding processes as abnormal.

[0014] Preferably, the selection of the process reference record includes:

[0015] When the coating thickness grade of the current container house is higher than the benchmark grade of the same model, the reference weight of the pulley entering the groove stage and the support wheel contact stage is increased.

[0016] When the sealing strip assembly batch is the first piece batch or a changeover batch, increase the reference weight of the locking point approach stage;

[0017] When the welding cooling time is less than the preset stabilization time, the reference weight of the initial rotation of the side wall plate is increased.

[0018] Preferably, the angular position and travel position of the folding event are not used alone for threshold judgment, but are formed into an event sequence chain according to the order of rotation of the side wall panel, the order of entry of the pulley into the slide groove, the order of contact of the support wheel, and the order of approach of the locking point;

[0019] When the current event sequence chain has a combination of a previous event delayed and a subsequent event advanced relative to the process reference record, the combination is marked as a folding sequence offset.

[0020] Preferably, after marking the folding order offset, the direction of offset propagation is further determined:

[0021] If the hinge-side rotation angle lags behind and is accompanied by an increase in drive load, then the source of the offset is directed to the hinge coaxiality.

[0022] If the pulley enters the groove position prematurely and the vibration signal of the support wheel increases, the source of the offset will be pointed to the groove spacing or the deformation of the groove edge.

[0023] If the locking point is subjected to force in advance and the side wall panel angle has not yet reached the locking angle, then the source of the offset will be directed to the compression of the sealing strip or the installation position of the lock seat.

[0024] Preferably, when the source of the offset cannot be uniquely determined, the control trial folding mechanism performs low-speed retraction and re-advancement before and after the current folding position, and compares the event sequence chain of the retraction process with that of the re-advancement process;

[0025] If the same folding event is still earlier or later in the same position when the retraction is followed by the advancement, it is confirmed as an assembly deviation.

[0026] If the offset position changes with the propulsion speed, it is confirmed as a temporary blockage or foreign object interference.

[0027] Preferably, the early warning information is categorized into review early warning, suspension early warning, and shutdown early warning according to the source of the deviation and the degree of risk.

[0028] Output a review warning when only a single event sequence offset exists;

[0029] When two consecutive events are offset in sequence and continue to occur after a slow rollback, a pause warning is output.

[0030] When the locking point is subjected to force in advance and the driving load continues to increase, a shutdown warning is output, and the trial folding mechanism is prohibited from continuing to apply pressure in the locking direction.

[0031] Preferably, after outputting a pause warning or shutdown warning, the current container house is transferred to the corresponding verification workstation;

[0032] Among them, the hinge coaxiality risk corresponds to the hinge pin insertion resistance and hinge seat spacing verification; the slide groove spacing risk corresponds to the slide groove opening width and pulley wear verification; and the sealing strip compression risk corresponds to the sealing strip height, lock seat position and lock tongue entry depth verification.

[0033] Preferably, after the verification station completes the adjustment, the trial folding is performed again;

[0034] The record will only be used as candidate data for subsequent reference records if the event sequence chain in the re-folding process is restored to the allowable range of the corresponding process reference record and the verification item is marked as qualified.

[0035] Records that fail the review are only used for anomaly tracing and will not be used to update the folding order of qualified container houses of the same model.

[0036] A monitoring and early warning system for foldable container house production equipment, applied to any of the monitoring and early warning methods for foldable container house production equipment, includes a trial folding monitoring module, a process history recall module, an event sequence generation module, an offset judgment module, a low-speed verification control module, an early warning output module, and a verification record management module.

[0037] The trial folding monitoring module is used to acquire side wall angle, pulley stroke, support wheel contact status, locking point force, drive load and acoustic vibration signals when the trial folding mechanism is in operation;

[0038] The process history recall module is used to recall the welding cooling time, spraying thickness grade, sealing strip assembly batch, and hinge pin batch of the current container house.

[0039] The event sequence generation module is used to generate the event sequence chain of the current container house;

[0040] The offset determination module is used to determine the folding order offset and the source of the offset;

[0041] The low-speed verification control module is used to control the trial folding mechanism to perform low-speed retraction and re-advancement.

[0042] The early warning output module is used to output review early warnings, pause early warnings, or shutdown early warnings;

[0043] The review record management module is used to manage review results and control whether qualified records are included in subsequent reference records.

[0044] The technical effects and advantages of this invention are as follows:

[0045] (1) This invention identifies multiple folding events, such as the rotation of the side wall panel, the pulley entering the groove, the support wheel abutting the edge of the groove, the folding of the diagonal brace, and the approach of the locking point. It also determines the folding sequence deviation based on the sequential relationship between each folding event. Compared with relying solely on current, pressure, or end-point alarm signals, this invention can identify potential jamming risks before the load is significantly exceeded, detect abnormalities in hinge coaxiality, groove spacing, sealing strip compression, or locking seat position in advance, and reduce the risk of hinge damage, groove deformation, and sealing strip damage during trial folding.

[0046] (2) When judging the folding sequence deviation, the present invention combines the welding cooling time, spraying thickness grade, sealing strip assembly batch and hinge pin batch, and selects qualified trial folding records with similar previous process history as references, instead of using a fixed threshold for judgment. This can distinguish between normal process differences and real assembly abnormalities, avoid misjudging normal resistance changes caused by differences in spraying thickness, sealing strip batch or welding cooling state as faults, and improve the accuracy of early warning judgment.

[0047] (3) After the folding sequence is deviated, the present invention performs a review by slow retraction and re-advancement. Based on whether the deviation occurs repeatedly in the same position and whether it changes with the advance speed, it distinguishes assembly deviation, temporary obstruction and foreign object interference. At the same time, the warning results are mapped to specific review directions such as hinge coaxiality, groove spacing or sealing strip compression, so as to avoid blindly stopping the machine for repair or continuing to force folding, thereby improving fault location efficiency and batch production stability. Attached Figure Description

[0048] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention, but do not constitute a limitation thereof. In the drawings:

[0049] Figure 1 This is a flowchart of the early warning process for folding event sequence offset according to the present invention;

[0050] Figure 2 This is a flowchart illustrating the selection of reference records based on the preceding process history of the present invention.

[0051] Figure 3 This is a flowchart of the low-speed verification and graded early warning process of the present invention. Detailed Implementation

[0052] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0053] This invention provides, for example Figures 1-3 The method for monitoring and early warning of foldable container house production equipment shown includes:

[0054] When the test folding mechanism drives the container to be tested to move from the unfolded state to the packed state, the rotation of the side wall panel, the entry of the pulley into the slide groove, the support wheel abutting the edge of the slide groove, the folding of the diagonal brace and the approach of the locking point are successively determined as folding events.

[0055] Based on the angular position, travel position, locking point force, driving load and acoustic vibration signal corresponding to each folding event, determine the current folding sequence offset of the container house;

[0056] The folding sequence offset is compared with the folding sequence of qualified container houses of the same model under the same prior process history. When at least two of the following are continuously associated: hinge rotation lag, pulley or support wheel being stressed in advance, and locking point contacting in advance, it is determined that there is a risk of folding jamming, and warning information corresponding to hinge coaxiality, slide groove spacing or sealing strip compression is output.

[0057] In one embodiment, after the foldable container house completes welding, spraying, sealing strip assembly, hinge assembly, and locking point assembly, it is sent to the trial folding and packing station. The trial folding mechanism is connected to the top frame, side wall panels, or bottom frame of the container house and drives the container house to move from the unfolded state to the packed state. During this process, the monitoring unit no longer uses the final folding signal or whether the driving load exceeds the limit as the basis for judgment. Instead, it divides the actions with sequential relationship during the folding process into multiple folding events, including the side wall panel starting to rotate and entering the predetermined angle range, the pulley entering the corresponding slide groove, the support wheel abutting the edge of the slide groove, the diagonal brace retracting with the side wall panel, and the locking point approaching the locking seat, etc.

[0058] Specifically, angle detection devices can be set at the hinge of the side wall panel, stroke detection devices can be set at the slide or pulley seat, and force detection devices can be set at the locking point or locking seat. The driving load of the test folding mechanism and the sound and vibration signals near the slide, hinge, and locking point are collected. The control unit determines the order and corresponding position of each folding event based on the above signals, forming the current folding sequence relationship of the container house. When the side wall panel has not yet reached the normal angle but the pulley or support wheel has already been stressed in advance, or when the locking point has already contacted the locking seat before the side wall panel reaches the predetermined locking posture, it indicates that the connection relationship between the folding actions has shifted.

[0059] Furthermore, the control unit uses the folding sequence relationship of qualified container houses of the same model under the same or similar prior process history as a reference. The prior process history includes welding cooling time, spraying thickness grade, sealing strip assembly batch, hinge pin batch, etc. In this way, normal resistance changes caused by slightly larger spraying thickness, differences in sealing strip batches, or different welding cooling states can be avoided from being misjudged as faults. If the current container house shows at least two consecutive correlations with the reference relationship, such as hinge rotation lag, pulley or support wheel being stressed in advance, or locking point contacting in advance, then it is determined that the abnormality is not a single signal fluctuation, but rather a risk of transmission jamming in the folding action chain.

[0060] With the above settings, this implementation can identify abnormal folding sequence before the driving load of the test folding mechanism is significantly exceeded, and output corresponding warnings based on the abnormal combinations. For example, when the hinge rotation is delayed and the subsequent pulley is subjected to force prematurely, it prompts to check the hinge coaxiality; when the pulley or support wheel is subjected to force prematurely and accompanied by increased sound vibration, it prompts to check the groove spacing or groove edge deformation; when the locking point contacts prematurely, it prompts to check the sealing strip compression or lock seat installation position. As a result, production personnel can intervene in time before the container house is forcibly folded, reducing the risk of hinge damage, groove deformation, sealing strip damage and locking point misalignment, and improving the accuracy of batch factory test folding inspection and rework positioning efficiency of folding container houses.

[0061] The determination of the folding order offset includes:

[0062] First, select records from the trial folding records of qualified container houses that have the same container size, folding direction, hinge specifications and locking point arrangement as the current container house to form a basic reference record;

[0063] Then, based on the current welding cooling time, spraying thickness grade, sealing strip assembly batch, and hinge pin batch of the container house, select the corresponding process reference record from the basic reference record to avoid misjudging the normal resistance difference caused by different preceding processes as abnormal.

[0064] In one implementation, to determine the current folding sequence deviation of the container house, the control unit does not directly compare the current trial folding data with all historical qualified data. Instead, it first performs layered screening of the trial folding records of qualified container houses. First, it screens according to structural conditions such as container size, folding direction, hinge specifications, and locking point arrangement to obtain basic reference records that are consistent with the current container house in terms of basic folding structure. Among them, the container size affects the rotation radius and folding stroke of the side wall panel, the folding direction affects the order in which the pulleys enter the slide, the hinge specifications affect the rotation resistance and angle change characteristics, and the locking point arrangement affects the force position when the locking points approach. Therefore, by first screening through the above structural conditions, it can be ensured that the reference records are comparable to the current container house.

[0065] After establishing the basic reference record, the control unit further reads the previous process history of the current modular house, including welding cooling time, spray coating thickness level, sealing strip assembly batch, and hinge pin batch. It then selects records from the basic reference record that are the same as or similar to the above process history as process reference records. For example, when the welding cooling time is short, there may still be a slight deformation recovery process in the frame or hinge installation area; when the spray coating thickness is large, the fit clearance near the pulley, slide, or locking point may decrease; the hardness or height difference of sealing strips from different batches will affect the compression resistance during the locking point approach stage; and different hinge pin batches may affect the smoothness of hinge rotation. By introducing these process history conditions, the reference object can be made closer to the actual production state of the current modular house.

[0066] By employing the above method, this implementation can avoid misjudging normal resistance differences caused by different preceding processes as folding anomalies. For example, if the current container house experiences a slight increase in load when the pulley enters the chute due to a higher coating thickness, but the sequence of folding events is still consistent with the reference records of similar processes, it will not be judged as an anomaly. If, under the same coating thickness and the same batch of sealing strips, the pulley is subjected to force prematurely, the locking point contacts prematurely, or the hinge rotates lags behind, it can more accurately point to assembly deviations or structural interference. Thus, the pertinence of folding sequence offset judgment is improved, false alarms are reduced, and subsequent warning results are more suitable for guiding the directional verification of hinges, chutes, sealing strips, or locking points.

[0067] The selection of process reference records includes:

[0068] When the coating thickness grade of the current container house is higher than the benchmark grade of the same model, the reference weight of the pulley entering the groove stage and the support wheel contact stage is increased.

[0069] When the sealing strip assembly batch is the first piece batch or a changeover batch, increase the reference weight of the locking point approach stage;

[0070] When the welding cooling time is less than the preset stabilization time, the reference weight of the initial stage of the side wall plate rotation is increased;

[0071] In one implementation, after the basic reference record is formed, the control unit adjusts the reference weight of different folding stages according to the current pre-process status of the container house. Specifically, when the current coating thickness level of the container house is higher than the benchmark level of the same model, it indicates that the fit clearance of the inner wall of the chute, the outer periphery of the pulley, or the contact area of ​​the support wheel may be reduced due to the increase in paint film thickness. At this time, the control unit increases the reference weight of the pulley entering the chute stage and the support wheel contacting stage, so that the focus of judgment is on whether the pulley contacts the edge of the chute too early, whether the support wheel generates contact resistance in advance, and whether the corresponding acoustic vibration signal is abnormally enhanced.

[0072] When the sealing strip assembly batch is the first batch or a changeover batch, the control unit increases the reference weight of the locking point approach stage because the height, hardness or rebound characteristics of the sealing strip may differ from those of the stable batch. It focuses on judging whether the locking point contacts the locking seat before the side wall plate reaches the normal locking posture, or whether the locking point is subjected to force earlier than the reference record of the same process, so as to identify problems such as excessive compression of the sealing strip and deviation of the locking seat installation position in a timely manner.

[0073] When the welding cooling time is less than the preset stabilization time, the frame of the container house, the hinge seat or the connection area of ​​the side wall panel may still have a post-weld deformation release process. The control unit increases the reference weight of the initial stage of the side wall panel rotation and focuses on judging whether there is hinge rotation lag, inconsistent left and right rotation or abnormal increase of initial stage drive load in the side wall panel folding stage.

[0074] With the above settings, this implementation does not adopt a uniform judgment standard for all folding stages. Instead, it dynamically highlights the folding stages that are easily affected based on the actual impact of spraying, sealing strip assembly, and welding cooling on the folding action. This reduces false alarms caused by normal process differences and improves the identification sensitivity when early abnormalities occur in pulleys, support wheels, locking points, or hinges, making the warning results more accurately correspond to specific verification directions such as groove gaps, sealing compression, or hinge assembly.

[0075] Among them, the angle position and travel position of the folding event are not used for threshold judgment alone, but form an event sequence chain according to the order of rotation of the side wall panel, the order of entry of the pulley into the slide groove, the order of contact of the support wheel, and the order of approach of the locking point;

[0076] When the current event sequence chain has a combination of a previous event being delayed and a subsequent event being advanced relative to the process reference record, the combination is marked as a folding sequence offset;

[0077] In one implementation, after the control unit acquires the side wall panel angle position, pulley travel position, support wheel contact position, and locking point approach position, it does not use the above position data as independent thresholds for judgment. Instead, it generates an event sequence chain according to the succession relationship of each action in the normal folding process. The event sequence chain is used to represent the sequential process of the side wall panel first entering the rotation state, then the pulley entering the corresponding slide groove, the support wheel contacting the edge of the slide groove, and finally the locking point gradually approaching the locking seat.

[0078] Specifically, the control unit confirms the side wall panel rotation event based on the angle detection device, the pulley entering the slide groove event based on the stroke detection device, the support wheel contacting event based on the contact signal or acoustic vibration change at the support wheel, and the locking point approaching event based on the lock point force change. It then generates the current event sequence chain according to the order of occurrence and corresponding position of each event. This event sequence chain is compared with the normal event sequence chain in the process reference record to determine whether the current folding action of the container house still maintains the normal connection relationship.

[0079] When the current event sequence chain contains a combination of a delayed preceding event and an advanced following event relative to the process reference record, the control unit marks this combination as a folding sequence offset. For example, if the side wall panel rotation angle has not yet reached the normal position in the process reference record, but the pulley has already entered the chute and generated force, it indicates that the connection between the side wall panel rotation and the pulley introduction has shifted. Or, if the support wheel has not yet formed contact in the normal position, but the locking point has already contacted the locking seat, it indicates that there may be an excessively thick sealing strip or a locking seat position deviation at the end of the folding.

[0080] With the above settings, this implementation can avoid misjudgment caused by relying solely on a certain angle value or stroke value to determine anomalies. Even if the position of a single folding event is still within the allowable range, it can still be identified as long as there is an abnormal change in the sequential relationship between it and the preceding and following folding events. As a result, the transmission jamming trend in the folding action chain can be detected earlier. It is especially suitable for folding test folding scenarios of folding box houses where there is a continuous cooperation relationship between hinges, pulleys, support wheels and locking points, thereby improving the sensitivity and accuracy of early warning.

[0081] After marking the folding order offset, the direction of offset propagation is further determined:

[0082] If the hinge-side rotation angle lags behind and is accompanied by an increase in drive load, then the source of the offset is directed to the hinge coaxiality.

[0083] If the pulley enters the groove position prematurely and the vibration signal of the support wheel increases, the source of the offset will be pointed to the groove spacing or the deformation of the groove edge.

[0084] If the locking point is subjected to force in advance and the side wall panel angle has not yet reached the locking angle, then the source of the offset will be directed to the compression of the sealing strip or the installation position of the lock seat.

[0085] In one implementation, after the control unit marks the folding sequence offset, it further determines the source of the offset based on the location and transmission direction of the abnormal signal during the folding action. Specifically, when the angle detection device shows that the rotation angle of the hinge side panel is lagging behind the process reference record, and the driving load of the trial folding mechanism continues to rise, it indicates that the driving force is mainly consumed in the initial stage of hinge rotation. The control unit points to the source of the offset as an abnormality in hinge coaxiality, such as the hinge seat being installed skewed, the pin not being properly inserted, or the rotation resistance of the left and right hinges being inconsistent.

[0086] When the stroke detection device shows that the pulley enters the chute position earlier than the process reference record, and the acoustic vibration signal near the support wheel is enhanced, it indicates that the pulley or support wheel has already contacted or rubbed against the edge of the chute before reaching the normal guide position. The control unit points to the source of this offset as insufficient chute spacing, chute edge deformation, or pulley installation position deviation. At this time, the warning information can remind production personnel to focus on checking the chute opening width, chute straightness, and installation height of pulleys and support wheels.

[0087] When the locking point force detection device shows that the locking point is subjected to force in advance, but the side wall plate angle has not yet reached the normal locking angle, it indicates that the contact between the locking point and the lock seat is earlier than the normal locking process. The control unit points to the source of this offset as excessive compression of the sealing strip, deviation of the lock seat installation position, or abnormal entry path of the lock tongue.

[0088] With the above settings, this implementation method can not only determine whether there is a folding sequence deviation in the current container house, but also determine the possible source of the abnormality based on the transmission characteristics of the deviation between the hinge, the slide, and the locking point. This avoids attributing all jamming to a drive mechanism failure. As a result, the warning information can be directly matched with the verification items such as hinge coaxiality, slide spacing, or sealing strip compression, improving the efficiency of rework positioning and reducing hinge squeezing, slide deformation, and sealing strip damage caused by forced folding.

[0089] When the source of the offset cannot be uniquely determined, the control trial folding mechanism performs low-speed retraction and re-advancement before and after the current folding position, and compares the event sequence chain of the retraction process with that of the re-advancement process;

[0090] If the same folding event is still earlier or later in the same position when the retraction is followed by the advancement, it is confirmed as an assembly deviation.

[0091] If the offset position changes with the propulsion speed, it is confirmed as a temporary blockage or foreign object interference;

[0092] In one implementation, when the control unit cannot uniquely determine the source of the offset based on the hinge angle, pulley travel, support wheel vibration, and locking point force signal, it does not immediately classify the current container house as a specific assembly defect. Instead, it controls the trial folding mechanism to perform a low-speed retraction and re-advancement near the current folding position. Specifically, the trial folding mechanism first retracts a distance in the opposite direction to the folding direction, causing the side wall panel, pulley, support wheel, and locking point to disengage from the current abnormal contact state. Then, it advances again in the packing direction at a speed lower than the normal trial folding speed, and re-collects the angle position, travel position, force signal, and vibration signal of each folding event to generate an event sequence chain during the re-advancement process.

[0093] The control unit compares the event sequence chain before retraction, during retraction, and during the next advance. If the same folding event is still in the same position earlier or later than before when advancing again, for example, the pulley is still under force in the same position earlier, or the locking point is still in contact earlier at the same angle, it indicates that the offset has repeatability and positional stability. It is usually related to assembly deviations such as the groove spacing, locking seat position, and hinge installation. If the offset position changes with the advance speed, or disappears abnormally when advancing again after retraction, it indicates that the offset is more likely caused by factors such as local adhesion of paint film, foreign object insertion, and temporary increase in friction.

[0094] By performing the aforementioned slow retraction and re-advancement verification, this implementation method can distinguish between assembly deviations and temporary blockages without forcibly continuing to fold, avoiding efficiency reduction caused by direct shutdown and rework due to a single abnormal signal, and also avoiding damage to components caused by continued pressure when actual assembly deviations exist, thereby improving the reliability of early warning judgments and the targeted nature of handling.

[0095] The early warning information is divided into review early warning, suspension early warning and shutdown early warning according to the source of deviation and the degree of risk.

[0096] Output a review warning when only a single event sequence offset exists;

[0097] When two consecutive events are offset in sequence and continue to occur after a slow rollback, a pause warning is output.

[0098] When the locking point is subjected to force in advance and the driving load continues to increase, a shutdown warning is output, and the trial folding mechanism is prohibited from continuing to apply pressure in the locking direction;

[0099] In one implementation, after determining the folding sequence offset and the source of the offset, the control unit outputs warning information in a graded manner according to the continuity, repetition and stress risk of the anomaly. The warning information includes at least a review warning, a pause warning and a shutdown warning. Different levels correspond to different equipment control strategies and manual handling requirements.

[0100] Specifically, when there is only a single event sequence deviation during the current trial folding process, such as only the pulley entering the slide groove position slightly ahead of time, or only the side wall panel rotating slightly behind in the initial stage, without being accompanied by continuous abnormal events, continuous increase in drive load, or premature force on the locking point, the control unit outputs a verification warning. At this time, the trial folding mechanism can continue to complete the current action in a low-risk state. Production personnel can manually observe or subsequently verify the corresponding parts according to the prompts to avoid unnecessary line stoppages caused by occasional signal fluctuations.

[0101] When two consecutive events of the current container house deviate in sequence, and after slow retreat and advance, the same deviation still occurs repeatedly in the same or similar position, the control unit outputs a pause warning. At this time, the trial folding mechanism stops moving in the packing direction and remains in a safe position, prompting production personnel to focus on checking items such as hinge coaxiality, slide groove spacing, support wheel installation height, sealing strip compression, or lock seat position. Since this type of abnormality has shown transmissibility and repetition, continuing to fold may amplify local interference. Therefore, it is necessary to complete the verification before resuming trial folding.

[0102] When the locking point is subjected to force in advance and the driving load of the trial folding mechanism continues to increase, the control unit outputs a shutdown warning and prohibits the trial folding mechanism from continuing to apply pressure in the locking direction. This situation indicates that the container house has not yet formed a normal locking posture, and the locking point, locking seat or sealing strip has been subjected to abnormal extrusion force. If the drive continues, it is easy to cause the locking point to be misaligned, the sealing strip to be crushed, the hinge to be twisted or the slide groove to be deformed.

[0103] Through the aforementioned graded early warning method, this implementation method can adopt a progressive control strategy according to the degree of risk. Low-risk anomalies only prompt for review to avoid frequent line stoppages; repetitive continuous deviations are promptly paused to facilitate positioning and rework; high-risk locking and squeezing will immediately stop the machine for protection. Thus, while ensuring the efficiency of mass production, it reduces structural damage caused by forced locking during trial folding and improves the safety and consistency of the foldable container house's factory inspection.

[0104] Among them, after outputting a pause warning or shutdown warning, the current container house will be transferred to the corresponding verification workstation;

[0105] Among them, the hinge coaxiality risk corresponds to the hinge pin insertion resistance and hinge seat spacing verification; the slide groove spacing risk corresponds to the slide groove opening width and pulley wear verification; and the sealing strip compression risk corresponds to the sealing strip height, lock seat position and lock tongue entry depth verification.

[0106] In one implementation, when the control unit outputs a pause warning or a shutdown warning, the current container house will no longer directly enter the subsequent packaging or warehousing process. Instead, it will be transferred to the corresponding verification station through a conveying mechanism, transfer trolley or workstation scheduling system. The verification station can automatically display the items to be verified according to the risk type indicated in the warning information, so that production personnel do not need to fully disassemble and inspect the entire folding structure, but can conduct targeted inspections on the source of the abnormality.

[0107] Specifically, when the warning information points to a risk of hinge coaxiality, the verification station checks the hinge pin insertion resistance and hinge seat spacing. Production personnel can determine whether there are problems such as hinge seat welding misalignment, misalignment of pin holes, or excessive hinge rotation resistance by performing pin insertion tests, measuring hinge seat spacing, or no-load swinging tests on the side wall panel. If the pin insertion resistance increases significantly, or the spacing between adjacent hinge seats is inconsistent, the hinge seat position can be corrected or the pin mating parts can be adjusted.

[0108] When the warning information points to a risk in the chute spacing, the verification station checks the chute opening width and the pulley wear condition. Production personnel can check the opening width, straightness and local deformation along the length of the chute, and check whether there are single-sided wear marks, abnormal extrusion marks or uneven rotation on the outer circumference of the pulley. If the chute opening width is too small in some areas or the pulley has obvious uneven wear, the edge of the chute can be reshaped, or the installation position of the pulley and support wheel can be adjusted.

[0109] When the warning information points to a risk of sealing strip compression, the verification station checks the sealing strip height, lock seat position, and lock tongue entry depth. Production personnel can check the protrusion height and compression uniformity of the sealing strip in the locking area, and check whether the lock seat installation position is offset and whether the lock tongue can smoothly enter the lock seat at the normal angle. If the sealing strip height is too large or the lock seat position is deviated, the sealing strip can be replaced, the lock seat adjusted, or the lock tongue entry path corrected.

[0110] With the above settings, the handling of pause warnings or shutdown warnings no longer relies on blind investigation based on manual experience. Instead, the folding sequence offset results are transformed into specific verification items for hinges, slides, sealing strips, and locking points. This can shorten the rework positioning time, reduce the number of repeated trial foldings, and prevent abnormal container houses from being packaged and shipped out without verification, thereby improving the consistency and quality traceability of folding container houses in mass production.

[0111] After the verification station completes the adjustment, the trial folding is performed again;

[0112] The record will only be used as candidate data for subsequent reference records if the event sequence chain in the re-folding process is restored to the allowable range of the corresponding process reference record and the verification item is marked as qualified.

[0113] Records that fail the review are only used for anomaly tracing and will not be used to update the folding sequence of qualified container houses of the same model.

[0114] In one implementation, after the verification station completes the adjustment of hinges, slides, sealing strips or locking points according to the early warning information, the current container house re-enters the trial folding and packing station and re-executes the trial folding process from the unfolded state to the packed state. During the re-trial folding, the control unit collects the angle position, stroke position, locking point force, driving load and sound and vibration signals of folding events such as side wall panel rotation, pulley entering slide, support wheel touching the edge of slide, diagonal brace closing and locking point approaching, and regenerates the event sequence chain.

[0115] The control unit compares the event sequence chain obtained from the re-folding with the process reference record corresponding to the container house. If the order of each folding event is restored to the allowable range of the process reference record, and the corresponding verification item in the verification station has been marked as qualified, such as normal hinge pin insertion resistance, qualified hinge seat spacing, qualified slide groove opening width, no abnormal wear of pulleys, qualified sealing strip height, qualified lock seat position, or qualified lock tongue entry depth, then the adjustment of the container house is deemed effective. At this time, the re-folding record can be used as candidate data for subsequent reference records, but it still needs to be confirmed together with other qualified records of the same batch or model before it can be used to update the folding sequence relationship of qualified container houses of the same model.

[0116] If the event sequence chain still deviates after re-folding, or if the event sequence chain is temporarily restored but the review item is not marked as qualified, the record will not be used as a qualified reference record, but will only be saved as an anomaly traceability record. The anomaly traceability record can be associated with the current container house number, previous process history, warning type, review item, adjustment content and re-folding result, and can be used for subsequent analysis of whether there are concentrated quality problems in the assembly of hinges, slides, sealing strips or locking points in the same batch.

[0117] Through the above settings, this implementation method can prevent trial folding data that has not been completely eliminated from entering the qualified reference library, avoid the subsequent judgment criteria from being erroneously relaxed by abnormal data. At the same time, only when the folding event sequence returns to normal and the review items are qualified, the record is allowed to be used as candidate reference data, thereby ensuring the reliability and stability of the reference record, improving the accuracy of subsequent judgment of the folding sequence deviation of the same model of container house, and enhancing the quality traceability capability in the mass production process.

[0118] A monitoring and early warning system for foldable container house production equipment, applicable to any monitoring and early warning method for foldable container house production equipment, includes a trial folding monitoring module, a process history recall module, an event sequence generation module, an offset judgment module, a low-speed verification control module, an early warning output module, and a verification record management module;

[0119] The trial folding monitoring module is used to acquire side wall angle, pulley stroke, support wheel contact status, locking point force, drive load and acoustic vibration signals when the trial folding mechanism is in operation;

[0120] The process history recall module is used to recall the welding cooling time, spraying thickness grade, sealing strip assembly batch, and hinge pin batch of the current prefabricated house;

[0121] The event sequence generation module is used to generate the event sequence chain for the current container house;

[0122] The offset determination module is used to determine the folding order offset and the source of the offset;

[0123] The low-speed verification control module is used to control the trial folding mechanism to perform low-speed retraction and re-advancement;

[0124] The early warning output module is used to output review early warnings, pause early warnings, or shutdown early warnings;

[0125] The review record management module is used to manage review results and control whether qualified records are included in subsequent reference records;

[0126] In one embodiment, the monitoring and early warning system is installed on the trial folding and packaging production line of the foldable container house, and is communicatively connected to the trial folding mechanism, the production history database, the verification station and the alarm display terminal. The trial folding monitoring module may include an angle sensor, a stroke sensor, a contact detection component, a force detection component, a drive load acquisition unit and an acoustic vibration acquisition unit, which are used to acquire the side wall angle, pulley stroke, support wheel contact status, locking point force, drive load and acoustic vibration signals during the operation of the trial folding mechanism.

[0127] The process history retrieval module is used to retrieve information such as welding cooling time, spraying thickness grade, sealing strip assembly batch and hinge pin batch from the production history database according to the current container house number or production batch, so that subsequent judgments can be made in conjunction with the previous process status. The event sequence generation module identifies folding events such as side wall panel rotation, pulley entering the slide groove, support wheel touching the edge of the slide groove, diagonal brace folding and locking point approaching, based on the data collected by the trial folding monitoring module, and generates the event sequence chain of the current container house according to the order of occurrence of each event.

[0128] The offset judgment module compares the current event sequence chain with the corresponding process reference record to determine whether there is a folding sequence offset. Based on the hinge side rotation angle, pulley entry position, support wheel vibration signal and locking point force state, it determines whether the offset source points to the hinge coaxiality, slide groove spacing, slide groove edge deformation, sealing strip compression amount or locking seat installation position. If the offset source cannot be uniquely determined, the low-speed verification control module controls the trial folding mechanism to perform low-speed retraction and re-advancement near the current folding position, and feeds back the re-collected event sequence chain to the offset judgment module for verification.

[0129] The early warning output module outputs review early warning, pause early warning, or shutdown early warning based on the source of the offset and the degree of risk. It can also send the early warning information to the display terminal or review workstation. The review record management module is used to record review items, adjusted content, re-folding results and qualified marks, and to control whether qualified records are included in subsequent reference records.

[0130] Through the above system settings, each module can form a closed-loop process from trial folding data collection, process history matching, event sequence generation, offset source judgment, low-speed review, hierarchical early warning to review record management. As a result, the system can not only detect whether the folding action is abnormal, but also locate the abnormality to the specific review direction, reducing blind manual investigation; at the same time, it avoids abnormal records from entering qualified reference data, improving the accuracy of subsequent monitoring and early warning of the same type of container house and the stability of mass production.

[0131] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A monitoring and early warning method for foldable container house production equipment, characterized in that, include: When the test folding mechanism drives the container to be tested to move from the unfolded state to the packed state, the rotation of the side wall panel, the entry of the pulley into the slide groove, the support wheel abutting the edge of the slide groove, the folding of the diagonal brace and the approach of the locking point are successively determined as folding events. Based on the angular position, travel position, locking point force, driving load and acoustic vibration signal corresponding to each folding event, determine the current folding sequence offset of the container house; The folding sequence offset is compared with the folding sequence of qualified container houses of the same model under the same prior process history. When at least two of the following are continuously associated: hinge rotation lag, pulley or support wheel being stressed in advance, and locking point contacting in advance, it is determined that there is a risk of folding jamming, and warning information corresponding to hinge coaxiality, slide groove spacing or sealing strip compression is output.

2. The monitoring and early warning method for a foldable container house production equipment according to claim 1, characterized in that, The determination of the folding order offset includes: First, select records from the trial folding records of qualified container houses that have the same container size, folding direction, hinge specifications and locking point arrangement as the current container house to form a basic reference record; Then, based on the current welding cooling time, spraying thickness grade, sealing strip assembly batch, and hinge pin batch of the container house, select the corresponding process reference record from the basic reference record to avoid misjudging the normal resistance difference caused by different preceding processes as abnormal.

3. The monitoring and early warning method for a foldable container house production equipment according to claim 2, characterized in that, The selection of the process reference record includes: When the coating thickness grade of the current container house is higher than the benchmark grade of the same model, the reference weight of the pulley entering the groove stage and the support wheel contact stage is increased. When the sealing strip assembly batch is the first piece batch or a changeover batch, increase the reference weight of the locking point approach stage; When the welding cooling time is less than the preset stabilization time, the reference weight of the initial rotation of the side wall plate is increased.

4. The monitoring and early warning method for a foldable container house production equipment according to claim 3, characterized in that, The angular and travel positions of the folding events are not used alone for threshold judgment, but rather form an event sequence chain according to the order of side wall panel rotation, the order of pulleys entering the slide groove, the order of support wheels abutting, and the order of locking points approaching. When the current event sequence chain has a combination of a previous event delayed and a subsequent event advanced relative to the process reference record, the combination is marked as a folding sequence offset.

5. The monitoring and early warning method for a foldable container house production equipment according to claim 4, characterized in that, After marking the folding order offset, the direction of offset propagation is further determined: If the hinge-side rotation angle lags behind and is accompanied by an increase in drive load, then the source of the offset is directed to the hinge coaxiality. If the pulley enters the groove position prematurely and the vibration signal of the support wheel increases, the source of the offset will be pointed to the groove spacing or the deformation of the groove edge. If the locking point is subjected to force in advance and the side wall panel angle has not yet reached the locking angle, then the source of the offset will be directed to the compression of the sealing strip or the installation position of the lock seat.

6. The monitoring and early warning method for a foldable container house production equipment according to claim 5, characterized in that, When the source of the offset cannot be uniquely determined, the control trial folding mechanism performs low-speed retraction and re-advancement before and after the current folding position, and compares the event sequence chain of the retraction process with that of the re-advancement process; If the same folding event is still earlier or later in the same position when the retraction is followed by the advancement, it is confirmed as an assembly deviation. If the offset position changes with the propulsion speed, it is confirmed as a temporary blockage or foreign object interference.

7. The monitoring and early warning method for a foldable container house production equipment according to claim 1, characterized in that, The early warning information is categorized into review early warning, suspension early warning, and shutdown early warning based on the source of deviation and the degree of risk. Output a review warning when only a single event sequence offset exists; When two consecutive events are offset in sequence and continue to occur after a slow rollback, a pause warning is output. When the locking point is subjected to force in advance and the driving load continues to increase, a shutdown warning is output, and the trial folding mechanism is prohibited from continuing to apply pressure in the locking direction.

8. The monitoring and early warning method for a foldable container house production equipment according to claim 7, characterized in that, After issuing a pause warning or shutdown warning, the current container house will be transferred to the corresponding verification workstation. Among them, the hinge coaxiality risk corresponds to the hinge pin insertion resistance and hinge seat spacing verification; the slide groove spacing risk corresponds to the slide groove opening width and pulley wear verification; and the sealing strip compression risk corresponds to the sealing strip height, lock seat position and lock tongue entry depth verification.

9. The monitoring and early warning method for a foldable container house production equipment according to claim 8, characterized in that, After the verification station completes the adjustment, the trial folding is performed again; The record will only be used as candidate data for subsequent reference records if the event sequence chain in the re-folding process is restored to the allowable range of the corresponding process reference record and the verification item is marked as qualified. Records that fail the review are only used for anomaly tracing and will not be used to update the folding order of qualified container houses of the same model.

10. A monitoring and early warning system for foldable container house production equipment, characterized in that, A monitoring and early warning method for a foldable container house production equipment according to any one of claims 1-9 includes a trial folding monitoring module, a process history recall module, an event sequence generation module, an offset judgment module, a low-speed verification control module, an early warning output module, and a verification record management module. The trial folding monitoring module is used to acquire side wall angle, pulley stroke, support wheel contact status, locking point force, drive load and acoustic vibration signals when the trial folding mechanism is in operation; The process history recall module is used to recall the welding cooling time, spraying thickness grade, sealing strip assembly batch, and hinge pin batch of the current container house. The event sequence generation module is used to generate the event sequence chain of the current container house; The offset determination module is used to determine the folding order offset and the source of the offset; The low-speed verification control module is used to control the trial folding mechanism to perform low-speed retraction and re-advancement. The early warning output module is used to output review early warnings, pause early warnings, or shutdown early warnings; The review record management module is used to manage review results and control whether qualified records are included in subsequent reference records.

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