Concrete pole production full-process intelligent control system based on digital twinning

Abstract

The application relates to the technical field of intelligent manufacturing, and discloses a concrete electric pole production whole-process intelligent control system based on digital twinning, which comprises a production control host, a field acquisition device, an execution controller and multi-station production equipment which are connected in communication, the production control host is connected with the process completion state, the equipment safety interlocking state and the quality detection result of each station according to a unique batch number. The centrifugal stage acquires the large-end supporting radial acceleration, the small-end supporting radial acceleration, the driving current and the mold angular velocity, aligns the data according to the angular position and forms the axial same-rotation eccentric load, and the centrifuge and the mold conveying equipment are controlled according to the comparison result of the axial same-rotation eccentric load and the upper limit. After each centrifugal stage is completed, the system forms the whole-process qualified release result in combination with the process completion state, the centrifugal completion signal and the quality detection result. The application is used for the centrifugal control, the process interlocking and the batch release of the concrete electric pole production line.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, and more specifically, to an intelligent control system for the entire production process of concrete poles based on digital twins. Background Technology

[0002] A concrete pole production line typically completes the following steps sequentially: raw material metering, concrete mixing, preparation of the reinforcing steel frame and molds, concrete placement, mold closing, prestressing tensioning, centrifugal molding, steam curing, release of tension, demolding, and quality inspection. On-site equipment is mostly controlled by PLCs or industrial controllers for start / stop and safety interlocks. Centrifuges are generally operated by frequency converters according to preset low, medium, and high-speed programs. The production control host or manufacturing execution system is responsible for work order issuance, batch registration, process release, and result archiving. Newer production lines also integrate vibration acquisition channels, speed encoders, current sampling channels, and industrial networks to display equipment status, store trend data, or provide alarm information.

[0003] Centrifugal molding uses a closed, long conical steel mold, and the axial and circumferential distribution of wet concrete inside the mold cannot be directly observed by the operator. During low-speed pre-rotation and subsequent acceleration, uneven material distribution, mold joint impact, changes in roller contact, shaft disturbances, and vibrations transmitted from adjacent machines can all be reflected in the support response. Existing control programs mostly use the vibration amplitude of a single measuring point, fixed alarm values, rotational speed, or running time for judgment. When an amplitude increase occurs at a single measuring point, the controller has difficulty distinguishing between uneven material distribution and ordinary collisions or external disturbances, and it is also difficult to determine whether the anomaly is closer to the large end or the small end of the mold.

[0004] Some production lines simultaneously record the responses of the supports at both ends, the inverter drive current, and encoder data. However, each channel may have timestamps generated by different acquisition units, and variations in sampling period, buffer delay, and rotational speed can make it difficult to directly correlate data at the same moment. While the drive current can reflect load changes, it cannot independently provide axial position information; the responses of the supports at both ends can show differences, but it cannot independently confirm whether these differences repeat with mold rotation and are synchronized with the drive load. If each channel still alarms independently according to its own time sequence, the control results are easily affected by broadband noise, transient shocks, and vibrations from adjacent machines.

[0005] On the equipment control side, vibration monitoring, centrifuge speed programming, and mold-moving equipment are often managed by different control units. Alarms from the monitoring system typically require operator confirmation before a decision can be made to maintain the speed, stop for inspection, or return to the fabric placement station. There is a lack of stable closed-loop communication between the alarm status and the centrifuge controller and the mold-moving equipment controller. Once entering medium or high speed ranges, if the control system can only continue operating according to the fixed speed program, even if an anomaly is recorded, it may not be promptly translated into equipment actions such as freezing and accelerating, decelerating and stopping, or returning to the fabric placement station.

[0006] On the end-to-end management side, raw material metering, tensioning, centrifugation, steam curing, and quality inspection data may be stored separately in PLCs, production control hosts, testing equipment, or manual records. When batch numbers, timestamps, and process completion status are not consistent, measurement records during the centrifugation stage are difficult to reliably correspond to subsequent quality inspection results; if verification batches or batches shut down for equipment protection are not excluded, they may also enter the statistical range of subsequent control values. Summary of the Invention

[0007] This invention provides an intelligent control system for the entire production process of concrete poles based on digital twins, which solves the technical problems mentioned in the background art.

[0008] To achieve the above-mentioned objectives, the present invention provides the following technical solution.

[0009] A digital twin-based intelligent control system for the entire production process of concrete poles includes a production control host connected by communication, a field data acquisition device, an execution controller, and multi-station production equipment including a centrifuge and a formwork transport device. The production control host is used for: Create a digital twin object containing the process completion status, equipment safety interlock status and quality inspection results of each production station based on a unique batch number, and release or lock the process accordingly; The system receives the radial acceleration of the large-end support, the radial acceleration of the small-end support, the driving current, and the angular velocity of the mold from the field acquisition device. The angular position is formed by the angular velocity of the mold. The four measurement data are aligned according to the angular position within the complete rotation window of one revolution of the mold. The large-end co-rotation quantity, the small-end co-rotation quantity, and the current co-rotation quantity are extracted. The large-end co-rotation quantity and the small-end co-rotation quantity are combined into the co-rotation quantity of the two supports. The amplitude difference between the large-end co-rotation quantity and the small-end co-rotation quantity is used to form the two-end bias ratio relative to the total amplitude of the two. The current fluctuation ratio is formed by the ratio of the current co-rotation quantity to the root mean square of the current. The phase relationship between the co-rotation quantity of the two supports and the current co-rotation quantity forms the in-phase degree. The three factors form the axial co-rotation off-center load quantity that characterizes the direction and reliability of the axial off-center load. The absolute value of the axial rotation load is compared with the corresponding pole specifications and the upper limit of the centrifugation stage. The centrifuge and the moving model equipment are controlled by the actuator controller. When each centrifugation stage is completed and the absolute value of the axial rotation load does not exceed the upper limit of the release, the centrifugation completion signal is output. When all process completion statuses are met, the centrifugation completion signal has been output, and the quality inspection results are qualified, a qualified release result for the entire process is formed.

[0010] Compared with the prior art, the present invention has the following substantial features and significant progress: This invention acquires radial acceleration of the large-end support, radial acceleration of the small-end support, driving current, and mold angular velocity using a field acquisition device. These four measurements are aligned angularly within a complete rotation window. The axial rotational load is calculated using the offset ratio of both ends, the current fluctuation ratio, and the phase relationship between them. This reduces the likelihood of centrifugal intervention being directly triggered by ordinary collisions, broadband noise, or vibrations from adjacent machines. The comparison between the axial rotational load and the release limit is processed by the controller to perform actions such as centrifuge operation, holding, freezing acceleration, deceleration shutdown, and mold return to the material placement station. This allows the data processing results to be directly fed into the production equipment control. The production control host then associates the process completion status, equipment safety interlock status, quality inspection results, and control records with a unique batch number. Only existing production batches with satisfactory process completion status, qualified quality inspection results, and no equipment protection shutdowns are used to calibrate the release limit. This ensures consistency between centrifugal control, subsequent process interlocks, and batch release, resulting in a traceable, fully qualified release process. Attached Figure Description

[0011] Figure 1 This invention presents the system architecture and closed-loop control relationship diagram of the intelligent control system for the entire production process of concrete poles based on digital twins. Detailed Implementation

[0012] The following description is provided in conjunction with the accompanying drawings. It should be understood that the following embodiments are for illustrative purposes only and are not intended to limit the invention; those skilled in the art can make equivalent substitutions or combinations for the specific implementations.

[0013] This embodiment relates to an intelligent control system for the entire production process of concrete poles based on digital twins. The system is used in a concrete pole production line, producing concrete poles that have undergone processes including raw material metering, mixing, preparation of the reinforcing steel frame and molds, concrete placement, mold closing, tensioning, centrifugation, steam curing, release, demolding, and quality inspection. The system utilizes a production control host to perform batch-based association and program control of existing production stations, measurement channels, and actuators, enabling the state judgments during the centrifugation stage to be translated into actual actions of the centrifuge and mold-moving equipment.

[0014] like Figure 1 As shown, the system of this embodiment includes a production control host 100, a field acquisition device 200, an execution controller 300, and a multi-station production equipment 400 including a centrifuge 410 and a mold-moving device 420, all connected by communication. The production control host 100 is located at the batch association and control decision center of the system, the field acquisition device 200 is located at the measurement data collection side, the execution controller 300 is located at the equipment control command execution side, and the multi-station production equipment 400 is located at the process execution and status feedback side.

[0015] It should be noted that the wet concrete inside the closed long conical mold may generate a recurring axial off-center load during centrifugal molding, which is difficult to identify the direction and reliability of the axial off-center load by relying solely on a single support vibration measuring point or solely on the driving current. The production control host 100 receives the radial acceleration of the large end support, the radial acceleration of the small end support, the driving current, and the mold angular velocity through the field acquisition device 200. The angular position is determined by the mold angular velocity. Within the complete rotation window of one revolution of the mold, the four measurement data are aligned according to the angular position, and then the following are generated: large end rotation amount, small end rotation amount, current rotation amount, combined rotation amount of both supports, offset ratio of both ends, current fluctuation ratio, phase degree, and axial rotation off-center load. The production control host 100 compares the absolute value of the axial rotation off-center load with the corresponding pole specifications and the upper limit of release for the centrifugal stage, and controls the centrifuge 410 and the mold moving equipment 420 via the execution controller 300.

[0016] In this embodiment, the digital twin object uses a unique batch number as an index to store the process completion status, equipment safety interlock status, quality inspection results, centrifugal completion signal, four measurement data, axial rotation load, re-laying direction, and overall qualified release results for each production station. The unique batch number runs from the raw material metering station to the quality inspection station, enabling unified traceability of the process inputs, control actions, inspection outputs, and process release or lock-up status for the same concrete pole. The production control host 100 uses this information to release or lock the process, preventing downstream production stations from acting prematurely before upstream stations have met their requirements.

[0017] Furthermore, the implementation methods of the production control host 100 and the digital twin object are as follows: The production control host 100 can be implemented using an industrial computer, a production line main control server, or a control host with data storage and control decision-making capabilities. The production control host 100 includes a digital twin full-process control module, a centrifugal status formation module, and a centrifugal program control module. The digital twin full-process control module is used to create a digital twin object based on a unique batch number, call up the standard mix ratio, tensioning program, centrifugal speed program, steam curing program, and quality inspection items, and write various control commands and corresponding process completion statuses into the digital twin object. The centrifugal status formation module is used to add timestamps to four measurement data points, pair the four measurement data points at the same sampling time according to the timestamps and angular positions, and form the large-end rotational quantity, small-end rotational quantity, current rotational quantity, current root mean square, and combined rotational quantity of both supports. The centrifugal program control module is used to form the axial rotational offset load, compare the absolute value of the axial rotational offset load with the upper limit of release, and output signals to continue executing the centrifugal speed program, pause acceleration, maintain current low speed, freeze acceleration, safe deceleration program, re-laying direction, or centrifugation completion.

[0018] A digital twin object includes at least the process completion status of each production station, the equipment safety interlock status, and the quality inspection results. Production stations include raw material metering stations, mixing stations, steel reinforcement cage and mold stations, material placement stations, mold closing stations, tensioning stations, centrifugal stations, steam curing stations, tension release stations, mold dismantling stations, and quality inspection stations. Each production station has a status record in the digital twin object corresponding to a unique batch number. This status record describes whether the production station meets the conditions for proceeding to the next production station. The equipment safety interlock status describes whether the safety conditions related to the production station, such as protective doors, emergency stops, support positioning, kiln door interlocks, actuator malfunctions, and control confirmations, are normal. The quality inspection results describe the comparison results of the quality inspection station on dimensional groups, surface defects, and specimen strength.

[0019] During batch initialization, the production control host 100 receives the pole specifications for the current production batch and writes the pole specifications, standard mix proportions, tensioning program, centrifugal speed program, steam curing program, and quality inspection items into a digital twin object. The standard mix proportions are used for raw material metering and mixing; the tensioning program is used for prestressing tensioning; the centrifugal speed program is used for the centrifugation stage; the steam curing program is used for steam curing; and the quality inspection items are used for quality inspection. Preset process allowable ranges are written into the digital twin object along with the pole specifications and are provided by existing process settings in the standard mix proportions, tensioning program, and centrifugal speed program; preset quality inspection allowable ranges are written into the digital twin object along with the pole specifications and are provided by the current technical standards or enterprise process cards corresponding to the quality inspection items.

[0020] The digital twin end-to-end control module determines whether subsequent production workstations are allowed to operate based on the current workstation's process completion status. If the current workstation's process completion status is not yet met, the digital twin end-to-end control module locks the workstations following it. If any equipment's safety interlock status is abnormal, the digital twin end-to-end control module locks the workstation to which that equipment belongs and all subsequent workstations. If the quality inspection result is unqualified, the digital twin end-to-end control module locks the quality inspection workstation. When equipment safety interlock status is abnormal, process completion status is not yet met, and quality inspection result is unqualified simultaneously, the abnormal equipment safety interlock status takes precedence in locking, followed by the process completion status, and finally, the quality inspection result is unqualified, which results in locking at the quality inspection workstation. The digital twin end-to-end control module only releases the corresponding lock after the corresponding abnormal status is restored to normal and written into the digital twin object. When the current production batch has not yet achieved a fully qualified release result, the digital twin full-process control module prohibits the next production batch from entering the raw material metering station; after the current production batch achieves a fully qualified release result and all corresponding locks are released, the digital twin full-process control module releases the prohibition status on the next production batch.

[0021] Digital twin objects can be stored in the local database of the production control host 100, the production line data server, or the batch database of the manufacturing execution system. The storage implementation only requires the ability to associate the process completion status, equipment safety interlock status, quality inspection results, four measurement data, axial rotation offset load, release limit, centrifugal completion signal, and overall process qualified release results with a unique batch number.

[0022] Furthermore, the implementation method for full-process production station control is as follows: At the raw material metering station, the digital twin full-process control module calls the standard mix proportion to control raw material metering according to the unique batch number. The standard mix proportion includes the target feeding requirements for cement mass, sand mass, aggregate mass, water mass, and admixture mass. The production control host 100 sends weighing control commands to the raw material metering device, reads the measured weighing status returned by the raw material metering device, and writes the weighing completion result into the digital twin object. When the sand moisture content is obtained by the moisture content sensor, the production control host 100 determines the actual water addition amount according to the existing water correction rules; the existing water correction rules are the standard process rules in concrete production, used to ensure that the actual water addition amount matches the current sand moisture content.

[0023] At the mixing station, the digital twin full-process control module calls the standard mix proportion control for mixing. After all raw materials are fed in, the mixer runs for the preset mixing time, and the production control host 100 records the process completion status of the mixing station. If the weighing exceeds the limit or the mixer has not finished running, the digital twin full-process control module keeps the material placement station locked, preventing concrete that has not yet met the process requirements from entering the material placement station.

[0024] At the steel reinforcement cage and mold station, the steel reinforcement cage completes the main reinforcement cutting, upsetting, erection ring assembly, spiral reinforcement assembly, and cage formation according to the pole specifications. The mold completes the upper and lower mold cleaning, release agent spraying, end plate inspection, and mold positioning confirmation. The production control host 100 reads the cage specification confirmation signal, mold positioning signal, and process completion status, and binds the steel reinforcement cage to the current production batch. If the cage specification confirmation signal, mold positioning signal, or process completion status is not met, the digital twin full-process control module keeps the mold conveying mechanism stopped to prevent unqualified cages or improperly positioned molds from entering the material placement station.

[0025] At the concrete placement station, the concrete placement equipment adds concrete to the lower mold along the length of the mold, and the concrete placement weighing device records the weight of the concrete entering the mold. This weight is used to determine whether the amount of concrete added is within the preset process allowable range. If the weight is not within the preset process allowable range, the digital twin full-process control module does not output a release signal for the centrifugal placement station. Once the preset process allowable range is reached, the completion status of the concrete placement station is written into the digital twin object.

[0026] At the mold closing station, the mold closing equipment completes the upper mold positioning and bolt tightening, and the production control host 100 reads the mold closing position signal. The mold closing position signal is used to confirm that the mold has reached the mechanically closed state that allows it to enter the tensioning station and the centrifugal station. If the mold closing position signal is not met, the digital twin full-process control module will not output the centrifugal station release signal.

[0027] At the tensioning station, the tensioning machine loads the main reinforcement according to the tensioning program, continuously reading the tension force and elongation. The tension force and elongation are compared with their respective preset process allowable ranges. If the tension force or elongation is not within the corresponding preset process allowable range, the digital twin full-process control module does not output a centrifuge station release signal. Only when the mold insertion quality, tension force, and elongation are within their respective preset process allowable ranges, the mold closing signal is satisfied, and the equipment safety interlock status is normal, does the digital twin full-process control module output a centrifuge station release signal and control the centrifuge station to start based on the centrifuge station release signal.

[0028] At the steam curing station, the digital twin full-process control module invokes the steam curing program to control the steam curing process. After the molded electric pole enters the steam curing station, the production control host 100 executes static stop, heating, constant temperature, and cooling according to the steam curing program, and reads the curing temperature and curing time. If the curing temperature is not within the allowable range corresponding to the steam curing program, the production control host 100 adjusts the steam valve opening and controls the circulating fan; if the curing time does not meet the requirements of the steam curing program, the kiln door interlock remains locked.

[0029] At the tension release and demolding stations, the digital twin full-process control module controls the tension release and demolding based on the completion status of the steam curing station. The tension release station releases prestress in a predetermined sequence, and the demolding station opens the mold and removes the pole. Only after the completion status of the steam curing, tension release, and demolding stations is met does the digital twin full-process control module control the quality inspection station to obtain the external dimensions, surface defects, and specimen strength.

[0030] Furthermore, the implementation methods of the on-site data acquisition device 200 and the four measurement data are as follows: like Figure 1 As shown, the field acquisition device 200 includes a large-end radial acceleration acquisition component 210, a small-end radial acceleration acquisition component 220, a frequency converter current sampling channel 230, and a speed encoder 240. The large-end radial acceleration acquisition component 210 is located at a support vibration measuring point near the large end of the mold and is used to acquire the radial acceleration of the large-end support. The small-end radial acceleration acquisition component 220 is located at a support vibration measuring point near the small end of the mold and is used to acquire the radial acceleration of the small-end support. The frequency converter current sampling channel 230 is used to acquire the drive current. The speed encoder 240 is used to acquire and calculate the mold angular velocity.

[0031] The large-end radial acceleration acquisition component 210 is installed on the outside of the support unit fixing seat or bearing seat near the large end of the mold, while the small-end radial acceleration acquisition component 220 is installed on the outside of the support unit fixing seat or bearing seat near the small end of the mold. Both components have fixed support surfaces that do not rotate with the mold. The sensitive axis direction is consistent with the radial vibration direction of the corresponding support unit. The fixing method is a rigid fixation method using bolts, magnetic bases, or adhesive. Anti-loosening components, shielded cables, and cable clamps are used to prevent loosening of the acquisition components and interference between the cables and rotating parts of the mold. The acquisition components at both ends use the same installation method and the same sampling settings, making the radial acceleration of the large-end support and the radial acceleration of the small-end support comparable.

[0032] The radial acceleration of the large-end support is a measurement of radial acceleration collected from the vibration measuring point of the support near the large end of the mold, while the radial acceleration of the small-end support is a measurement of radial acceleration collected from the vibration measuring point of the support near the small end of the mold. Both are used to reflect the radial response generated at the supports at both ends of the long conical mold as the mold rotates. Because the large and small ends of the long conical mold differ in geometry, concrete distribution, and support stress, collecting the radial acceleration of the large-end and small-end supports separately provides a basis for determining the direction of axial eccentric load.

[0033] The drive current is a current measurement collected by the inverter current sampling channel 230 during the operation of the centrifuge 410 drive chain. The drive current reflects changes in the drive load. When the wet concrete is unevenly distributed along the circumference and repeatedly generates eccentric excitation as the mold rotates, the drive load will fluctuate with rotation, and the drive current will show corresponding fluctuations related to the mold rotation. The drive current is not used to directly determine whether the eccentric load is located at the large or small end of the mold, but rather to confirm whether the load fluctuations have characteristics related to mold rotation.

[0034] The mold angular velocity is the instantaneous angular velocity of the mold, acquired and calculated by the speed encoder 240. The mold angular velocity is used to establish the angular position, ensuring that the radial acceleration of the large-end support, the radial acceleration of the small-end support, and the drive current at different sampling times can be converted to the same mold rotational reference. Using the mold angular velocity to establish the angular position ensures that speed changes during the low, medium, or high-speed phases of the centrifugal rotation program do not disrupt the angular position alignment within the complete rotation window.

[0035] The centrifugal state formation module uses a unified clock to add timestamps to four measurement data points and pairs the four measurement data points at the same sampling time according to the timestamps and angular positions. The unified clock can be provided by the production control host 100, or by a PLC, industrial controller, or field acquisition device 200. The field acquisition device 200... Figure 1The internal collection terminal shown collects the data output by the large-end radial acceleration acquisition component 210, the small-end radial acceleration acquisition component 220, the inverter current sampling channel 230, and the speed encoder 240, so that the large-end support radial acceleration, small-end support radial acceleration, drive current, and mold angular velocity at each sampling moment correspond to the same time reference and the same angular position.

[0036] When the process completion status of the upstream production station is not met, any measurement data cannot be collected, or the equipment safety interlock status is abnormal, the digital twin full-process control module prohibits the centrifuge controller from starting the centrifuge 410. Any measurement data that cannot be collected includes the inability to collect the radial acceleration of the large end support, the radial acceleration of the small end support, the drive current, or the mold angular velocity. The criteria for failure to collect data include four consecutive missing sampling points, incorrect sampling timestamps, sampling values ​​exceeding the range of the acquisition component, sampling values ​​remaining unchanged for more than one complete rotation window, or communication timeout between the field acquisition device 200 and the production control host 100 exceeding one sampling interval. This prohibition rule prevents the axial rotational load from being incorrectly generated when necessary input is missing, and also prevents the centrifuge from entering the centrifugation stage when the equipment safety interlock status is abnormal.

[0037] Furthermore, the implementation method for angular position alignment and axial rotational offset load formation is as follows: The centrifugal state formation module aligns four measurement data points according to their angular positions within the complete rotation window of one mold revolution. The complete rotation window refers to a sampling window that covers the entire rotation process of the mold. Within this complete rotation window, the production control host 100 acquires the number of sampling points and the sampling interval, and recursively derives the angular position based on the mold's angular velocity. The angular position is formed using the following relationship: , where the angular position Indicates the first The mold corner position corresponding to each sampling point, corner position Indicates the first The mold rotation angle position and mold angular velocity corresponding to each sampling point Indicates the first The mold angular velocity corresponding to each sampling point, sampling interval Indicates the time interval between adjacent sampling points. Angular position. Before entering the complex exponential calculation, the values ​​are uniformly expressed in radians. When the speed encoder 240 outputs values ​​in revolutions per minute, revolutions per second, or angles, the production control host 100 first converts them into mold angular velocities in radians per second, and then recursively calculates the angular position according to the above relationship. Number of sampling points This represents the number of sampling points within the complete rotation window and is set to an integer not less than 32. The complete rotation window increments cumulatively from the window's starting point to the specified angular position. As a closure condition, the end point of the window corresponds to the position where the mold completes one revolution; if the last sampling point exceeds... The production control host 100 determines the four measurement data points at the end of the window by linear interpolation of adjacent sampling points.

[0038] The starting point of the complete rotation window is selected as the first valid angular position sampling point after the centrifuge 410 enters the stable low-speed pre-rotation, medium-speed, or high-speed stage. All sampling points within the complete rotation window must have the same unique batch number, continuous sampling timestamps, and valid flags; if any sampling point is missing, the timestamps are out of order, the sampled value exceeds the range of the acquisition component, or the valid flag is invalid, the complete rotation window will not participate in the release judgment. The sampling interval is determined by the sampling cycle of the field acquisition device 200 and remains consistent within the same complete rotation window; when the centrifuge speed program causes changes in the mold angular velocity, the angular position is still accumulated to the specified value. As a condition for the complete rotation window to close.

[0039] After the angular position is formed, the centrifugal state forming module forms the same rotational magnitude at the large end at the fundamental frequency of mold rotation based on the radial acceleration of the large end support within the same complete rotation window: Among them, the large-end rotation volume The radial acceleration of the large end support is represented by a complex number at the fundamental frequency of the mold rotation. Indicates the first Radial acceleration of the large end support at each sampling point, number of sampling points Indicates the number of sampling points within the complete rotation window, and the angular position. Indicates the first The mold corner position corresponding to each sampling point The unit is imaginary. The large-end rotation is used to extract the large-end support response that is synchronized with one revolution of the mold.

[0040] The centrifugal state formation module generates the small-end rotational magnitude at the fundamental frequency of mold rotation based on the radial acceleration of the small-end support within the same complete rotation window. Among them, the little-endian rotation is the same. The radial acceleration of the small end support is represented by a complex number at the fundamental frequency of the mold rotation. Indicates the first The radial acceleration of the small-end support at each sampling point. The small-end rotational magnitude is used to extract the small-end support response synchronized with one revolution of the mold. After the large-end and small-end rotational magnitudes are formed, the centrifugal state formation module combines the large-end and small-end rotational magnitudes into a combined rotational magnitude of the supports at both ends. The combined rotational magnitude of the supports at both ends can be formed by adding the large-end and small-end rotational magnitudes; its function is to obtain the rotational response jointly reflected by the supports at both ends.

[0041] The centrifugal state formation module first obtains the average value of the drive current within the complete rotation window: Among them, the average value of the drive current This represents the arithmetic mean of the driving current within the complete rotation window. Indicates the first The drive current at each sampling point. Removing the average value of the drive current can reduce the impact of the DC component of the drive current on the current-to-rotation ratio.

[0042] The centrifugal state formation module removes the average value of the drive current within the complete rotation window and then forms a current-rotational frequency at the fundamental frequency of mold rotation: Among them, current and rotational speed This represents the complex representation of the drive current at the fundamental frequency of mold rotation after removing the average value of the drive current. Indicates the first Drive current at each sampling point, average drive current This represents the average driving current within the same complete rotation window. Current-to-rotational-current ratio is used to reflect the fluctuations in the driving load that are synchronized with the mold rotation.

[0043] The centrifugal state formation module obtains the root mean square current within the complete rotation window: Among them, the root mean square current This represents the root mean square of the driving current within the complete rotation window. Indicates the first The drive current at each sampling point. The root mean square of the current is used to provide a normalized reference for the current fluctuation ratio, enabling proportional comparison of drive currents across different batches and different centrifugation stages.

[0044] The centrifugal state formation module uses the amplitude difference between the large-end and small-end rotational speeds relative to their total amplitude to form a bias ratio between the two ends: Among them, the two ends are biased towards the ratio This represents the ratio of the amplitude difference between the large-end and small-end rotational speeds relative to the total amplitude of the two; large-end rotational speed. This represents the complex number expression of the radial acceleration of the large end support at the fundamental frequency of the mold rotation, while the small end is the same as the rotational speed. This represents the radial acceleration of the small end support at the fundamental frequency of the mold rotation as a complex number. A deflection ratio greater than zero indicates that the amplitude of the rotation at the large end is greater than that at the small end; a deflection ratio less than zero indicates that the amplitude of the rotation at the small end is greater than that at the large end.

[0045] The centrifugal state formation module uses the ratio of current rotational speed to the root mean square current to form the current fluctuation ratio. Among them, the current fluctuation ratio This represents the ratio of the magnitude of the current-to-rotational-current to the root mean square of the current. This represents the complex representation of the drive current at the fundamental frequency of mold rotation after removing the average value of the drive current; the root mean square of the current. This represents the root mean square of the driving current within the complete rotation window. A larger current fluctuation ratio indicates that the fluctuation component in the driving current synchronized with the mold rotation is more pronounced.

[0046] The centrifugal state formation module establishes phase inertia based on the phase relationship between the combined rotational magnitude and the current rotational magnitude supported at both ends. Among them, the degree of in-phase This indicates the degree of phase correspondence between the combined rotational magnitude of the supports at both ends and the rotational magnitude of the current. The combined rotational magnitude of the supports at both ends is derived from the rotational magnitude of the larger end. Same rotational speed as little end Synthesis, current and rotation This represents the complex representation of the drive current at the fundamental frequency of mold rotation after removing the average value of the drive current. The complex number representing the conjugate of current and rotation. This indicates the real part. Phase coherence is used to suppress interference that does not repeat with the mold rotation angle, such as common impacts, broadband noise, or vibrations from adjacent machines.

[0047] The centrifugal state formation module uses the deflection ratio at both ends, the current fluctuation ratio, and the phase inclination to form the axial rotational off-center load, which characterizes the direction and reliability of the axial off-center load. Among them, axial co-rotation eccentric load The dimensionless control quantity representing the direction and reliability of axial off-center loading, with the two ends offset by a ratio. Indicates the axial direction, current fluctuation ratio This indicates the proportion of synchronous rotation fluctuations in the driving load, and the degree of synchronous rotation. This indicates the degree of phase correspondence between the combined rotational load at both ends and the rotational load of the current. When the axial rotational off-center load is greater than zero, it indicates a stronger rotational response at the large end; when the axial rotational off-center load is less than zero, it indicates a stronger rotational response at the small end. The absolute value of the axial rotational off-center load is used for comparison with the upper limit of the release.

[0048] When any normalized reference required to form the offset ratio, current fluctuation ratio, or phase integrability is zero and the corresponding parameter cannot be formed, the centrifugal state formation module marks the corresponding complete rotation window as having no effective excitation and excludes it from the release judgment. A normalized reference of zero includes the sum of the amplitudes of the large-end and small-end rotations being zero, the root mean square of the current being zero, the amplitude of the combined rotation of the two supports being zero, or the amplitude of the current rotation being zero. After a complete rotation window is marked as having no effective excitation, the centrifugal program control module re-forms the axial rotation offset load in the next complete rotation window; when three consecutive complete rotation windows are marked as having no effective excitation, the centrifugal program control module maintains the current low speed and prohibits the output of the centrifugation completion signal; when five consecutive complete rotation windows are marked as having no effective excitation, the centrifugal program control module controls the centrifuge controller to execute a safety deceleration program, causing the centrifuge 410 to decelerate to a stop.

[0049] Furthermore, the implementation methods for centrifugal program control and fabric re-laying direction are as follows: The execution controller 300 includes a centrifuge controller for controlling the centrifuge 410 and a mold-moving device controller for controlling the mold-moving device 420. The production control host 100 sends commands to the centrifuge 410 via the execution controller 300 to continue running, maintain, freeze speed-up or speed-down and stop, and sends commands to the mold-moving device 420 to deliver molds or return to re-laying.

[0050] During the low-speed phase of the centrifugation program, after the mold reaches the centrifugation station and the support is confirmed to be in place, the centrifuge controller first controls the centrifuge 410 to perform a low-speed pre-rotation. The centrifugation state formation module generates axial rotational offset load for each continuous complete rotation window. The centrifugation program control module compares the absolute value of the axial rotational offset load within each complete rotation window with the corresponding pole specification and the release limit for the centrifugation stage. The release limit is obtained by the production control host 100 from the release limit lookup table according to the pole specification of the current production batch and the current centrifugation stage.

[0051] When the absolute value of the axial rotational load does not exceed the upper limit of release within two consecutive complete rotation windows, the centrifugal program control module controls the centrifuge controller to continue executing the centrifugal speed program. Continuing to execute the centrifugal speed program means that the centrifuge 410 increases or maintains the speed according to the original low-speed, medium-speed, and high-speed programs, without causing additional shutdowns due to the judgment result of the axial rotational load.

[0052] When the absolute value of the axial co-rotational load exceeds the release limit within any complete rotation window, the centrifuge program control module pauses the speed increase and maintains the current low speed to regenerate the axial co-rotational load. Maintaining the current low speed means that the centrifuge 410 maintains the current mold angular velocity of the low-speed stage at which the limit was triggered, without further increasing the mold angular velocity, and continuously regenerates the axial co-rotational load for two complete rotation windows. If the absolute value of the axial co-rotational load in either of these two complete rotation windows still exceeds the release limit, the centrifuge program control module controls the centrifuge controller to execute a safety deceleration program, causing the centrifuge 410 to decelerate to a stop; if the absolute value of the axial co-rotational load in neither of these two complete rotation windows does not exceed the release limit, the centrifuge program control module allows the centrifuge controller to continue executing the centrifuge speed program.

[0053] The centrifugal program control module does not generate a re-laying direction when the axial rotational eccentric load is zero, and re-generates the axial rotational eccentric load in the next complete rotation window. A zero axial rotational eccentric load indicates that the large-end or small-end re-laying direction cannot be determined based on the positive or negative direction in the current complete rotation window, therefore a re-laying direction should not be generated.

[0054] If the absolute value of the axial rotational load after maintaining the current low speed still exceeds the upper limit of release and the centrifuge 410 has decelerated to stop, the centrifuge program control module will determine the re-laying direction as the large end re-laying direction when the axial rotational load is greater than zero, and determine the re-laying direction as the small end re-laying direction when the axial rotational load is less than zero. The mold moving equipment controller will then control the mold moving equipment 420 to send the mold back to the laying station for re-flattening according to the re-laying direction.

[0055] During the medium-speed or high-speed phase of the centrifugation speed program, the centrifugation program control module generates an axial co-rotational off-center load for each complete rotation window and freezes the speed increase when the absolute value of the axial co-rotational off-center load exceeds the release limit. Freezing the speed increase means that the centrifuge 410 maintains the current mold angular velocity of the medium-speed or high-speed phase at the time of the over-limit trigger, without further increasing the mold angular velocity, and continuously regenerates the axial co-rotational off-center load according to the complete rotation window. Only after the absolute value of the axial co-rotational off-center load in two consecutive complete rotation windows has recovered to below the release limit does the centrifugation program control module control the centrifuge controller to continue executing the centrifugation speed program. If the absolute value of the axial co-rotational off-center load still exceeds the release limit in five consecutive complete rotation windows, the centrifugation program control module controls the centrifuge controller to execute a safety deceleration program, causing the centrifuge 410 to decelerate to a stop. When all centrifugation phases are completed and the absolute value of the axial co-rotational off-center load does not exceed the corresponding release limit, the centrifugation program control module outputs a centrifugation completion signal.

[0056] Furthermore, the implementation method for updating the quality inspection and release limits is as follows: After the steam curing, tensioning, and demolding stations are all completed, the digital twin full-process control module controls the quality inspection station to acquire the external dimensions, surface defects, and specimen strength. The external dimensions consist of the pole length, large-end diameter, and small-end diameter. Surface defects consist of crack detection results, exposed rebar detection results, and missing piece detection results. The quality inspection station compares the pole length, large-end diameter, small-end diameter, crack detection results, exposed rebar detection results, missing piece detection results, and specimen strength with their respective preset quality inspection allowable ranges. These preset quality inspection allowable ranges are written into the digital twin object along with the pole specifications and quality inspection items, and are provided by the allowable requirements for pole length, large-end diameter, small-end diameter, crack detection results, exposed rebar detection results, missing piece detection results, and specimen strength in current technical standards or enterprise process cards.

[0057] The quality inspection station generates a qualified quality inspection result and writes it into the digital twin object only when all comparison results for pole length, large end diameter, small end diameter, crack detection results, exposed rebar detection results, defect detection results, and specimen strength are within the corresponding preset quality inspection allowable ranges. If any comparison result is not within the corresponding preset quality inspection allowable range, the quality inspection result is unqualified, the digital twin full-process control module locks the quality inspection station, and maintains the current production batch's review status.

[0058] The production control host 100 stores a release upper limit lookup table. Each entry in the table includes the corresponding pole specification, centrifugation stage, unique pre-configured release upper limit, number of calibration samples, calibration time, and calibration status. The centrifugation program control module retrieves the release upper limit from the lookup table based on the pole specification and current centrifugation stage of the current production batch. Low-speed, medium-speed, and high-speed stages each correspond to their respective release upper limits. When the number of calibration samples for a particular pole specification and centrifugation stage has not yet been reached, the release upper limit is determined by the unique pre-configured release upper limit given in the company's process card or historical qualified batches of the same specification.

[0059] The digital twin full-process control module only uses existing production batches where all process completion statuses at each production station are met, quality inspection results are qualified, and no equipment protection shutdowns have occurred as calibration samples for the release upper limit, and writes the calibrated release upper limit into the corresponding table entry. Production batches in the verification state, production batches with unqualified quality inspection results, production batches with equipment protection shutdowns, production batches that have not output centrifugation completion signals, and production batches whose any complete rotation window is marked as having no effective excitation and have not re-obtained a valid axial co-rotation off-center load are not used as calibration samples, thus avoiding abnormal states from entering the release upper limit update process.

[0060] The release limit is calibrated using the absolute value distribution of axial co-rotation off-center loads in existing production batches. For the same pole specification and the same centrifugal stage, after the production control host 100 accumulates no less than 30 calibration samples, the absolute values ​​of the axial co-rotation off-center loads corresponding to each calibration sample are arranged in ascending order, and the value corresponding to the 95th percentile is taken as the calibrated release limit. When the sorting position corresponding to the 95th percentile is not an integer, the value corresponding to the larger sorting position between two adjacent sorting positions is taken as the calibrated release limit. The production control host 100 recalibrates the release limit every 10 new calibration samples and writes the calibrated release limit, the number of calibration samples, and the calibration time into the corresponding entry in the release limit lookup table.

[0061] When all process completion statuses are met, the centrifugation completion signal has been output, and the quality inspection result is qualified, the production control host 100 generates a full-process qualified release result. A full-process qualified release result indicates that the current production batch has completed all necessary production stations, the centrifugation stage did not continue with abnormal acceleration under identifiable axial rotation and off-center load conditions, and the quality inspection station generated a qualified quality inspection result. If there are incomplete processes, abnormal equipment safety interlock status, no centrifugation completion signal output, or unqualified quality inspection results, the production control host 100 will not generate a full-process qualified release result.

[0062] As an optional implementation, the raw material metering station, mixing station, steel reinforcement cage and mold station, material placement station, mold closing station, and tensioning station of the current production batch have all met the process completion requirements. The equipment safety interlock status is normal, and the mold entry quality, tension force, and tension elongation are all within their respective preset process allowable ranges. After the centrifuge 410 undergoes low-speed pre-rotation, the centrifugal state formation module generates axial co-rotational off-center load within two consecutive complete rotation windows, and the absolute value of the axial co-rotational off-center load does not exceed the release limit. The centrifugal program control module controls the centrifuge 410 to continue executing the centrifugal speed program, and the absolute value of the axial co-rotational off-center load does not exceed the release limit during the medium-speed and high-speed stages. After all centrifugal stages are completed, a centrifugation completion signal is output, the subsequent quality inspection results are qualified, and the production control host 100 generates a full-process qualified release result.

[0063] As an optional implementation, the current production batch has received a release signal from the centrifuge station, and the centrifuge 410 begins low-speed pre-rotation. Within the first complete rotation window, the amplitude of the large-end rotational magnitude formed by the centrifugal state formation module is greater than the amplitude of the small-end rotational magnitude. The current fluctuation ratio indicates that the drive current exhibits rotational fluctuations, and the phase correlation indicates that the combined rotational magnitude of the supports at both ends has a phase correspondence with the current rotational magnitude. The axial rotational offset load is greater than zero, and the absolute value of the axial rotational offset load exceeds the release limit. The centrifugal program control module pauses the acceleration and maintains the current low speed to re-form the axial rotational offset load. If the absolute value of the axial rotational offset load still exceeds the release limit after retesting, the centrifuge 410 executes a safety deceleration program and stops. The re-laying direction is determined to be the large-end re-laying direction, and the mold transport device 420 sends the mold back to the laying station for re-flattening.

[0064] As an optional implementation, the amplitude of the small-end rotational speed generated by the centrifugal state forming module is greater than that of the large-end rotational speed. The current fluctuation ratio and phase inertia both indicate that the current fluctuation is related to the mold rotation. The axial rotational load is less than zero and the absolute value of the axial rotational load exceeds the release limit. When the absolute value of the axial rotational load still exceeds the release limit after maintaining the current low speed and the centrifuge 410 has decelerated to a stop, the centrifugal program control module determines the re-laying direction as the small-end re-laying direction, and the mold transport equipment controller controls the mold transport equipment 420 to send the mold back to the laying station for re-flattening.

[0065] As an optional implementation, if the absolute value of the axial co-rotational load does not exceed the release limit for two consecutive complete rotation windows in the low-speed stage, the centrifuge 410 has entered the medium-speed or high-speed stage. Subsequently, if the absolute value of the axial co-rotational load exceeds the release limit for the corresponding centrifugation stage in a certain complete rotation window, the centrifugation program control module does not immediately determine the re-distribution direction, but freezes the speed increase and continues to determine the axial co-rotational load for subsequent complete rotation windows. Only after the absolute value of the axial co-rotational load in two consecutive complete rotation windows has recovered to not exceed the release limit will the centrifugation program control module continue to execute the centrifugation speed program.

[0066] As an optional implementation, the field acquisition device 200 may fail to acquire any of the following: radial acceleration of the large-end support, radial acceleration of the small-end support, drive current, or mold angular velocity; or it may experience any of the following: four consecutive missing sampling points, out-of-order sampling timestamps, sampling values ​​exceeding the range of the acquisition component, sampling values ​​remaining unchanged for more than one complete rotation window, or communication timeouts exceeding one sampling interval. Because the four measurement data cannot be completely matched, the centrifugation state formation module cannot reliably generate axial rotational offset load. The digital twin full-process control module prohibits the centrifuge controller from starting the centrifuge 410, or maintains the current low speed once the centrifugation stage has begun; if an effective axial rotational offset load cannot be obtained after five consecutive complete rotation windows, the centrifugation program control module controls the centrifuge controller to execute a safety deceleration program, causing the centrifuge 410 to decelerate to a stop.

[0067] As an optional implementation, any normalized reference required to form the end-to-end bias ratio, current fluctuation ratio, or in-phase degree within a complete rotation window is zero. The centrifugal state formation module marks the corresponding complete rotation window as having no effective excitation and excludes it from the release judgment. The centrifugal program control module re-forms the axial rotational offset load in the next complete rotation window. If there is no effective excitation for three consecutive complete rotation windows, the centrifugal program control module maintains the current low speed and prohibits the output of the centrifugation completion signal; if there is no effective excitation for five consecutive complete rotation windows, the centrifugal program control module controls the centrifuge 410 to execute a safety deceleration program so that complete rotation windows lacking a valid judgment basis are not considered to meet the upper limit conditions for release.

[0068] As an optional implementation, if a safety interlocking status malfunctions at a production station in the current production batch, the digital twin full-process control module locks the production station to which the equipment belongs and all subsequent production stations. If the safety interlocking status malfunction occurs before the centrifuge 410 is started, the digital twin full-process control module prevents the centrifuge controller from starting the centrifuge 410; if the safety interlocking status malfunction occurs during the centrifugation stage, the centrifuge controller executes a stop or hold operation according to existing safety control requirements, and the production control host 100 does not output a centrifugation completion signal.

[0069] As an optional implementation, the centrifugation completion signal has been output, and the process completion status of the steam curing station, tension release station, and demolding station all meet the requirements. However, if any comparison result from the quality inspection station—such as pole length, large end diameter, small end diameter, crack detection result, exposed reinforcement detection result, defect detection result, or specimen strength—is not within the corresponding preset quality inspection allowable range, the quality inspection result is considered unqualified. The digital twin full-process control module locks the quality inspection station, does not generate a full-process qualified release result, and this production batch is not used as a calibration sample for the release upper limit.

[0070] It should be noted that the production control host 100, field acquisition device 200, execution controller 300 and multi-station production equipment 400 can be connected via industrial Ethernet, fieldbus, OPCUA or PLC communication network.

[0071] It should be noted that the large-end radial acceleration acquisition component 210 and the small-end radial acceleration acquisition component 220 can be industrial vibration acceleration sensors, installed at the support vibration measurement points near the large end and small end of the mold, respectively. The installation position should be determined based on the ability to stably acquire the radial vibration response at the corresponding support. The inverter current sampling channel 230 can be the internal current sampling channel of the centrifuge 410 inverter or an industrial current sampling module corresponding to the inverter output. The speed encoder 240 can be an existing speed encoder of the centrifuge 410 or an angular velocity detection device synchronized with the mold rotation.

[0072] It should be noted that the execution controller 300 can be implemented by a PLC, industrial controller, or distributed I / O controller. After receiving the control commands from the execution controller 300, the centrifuge controller controls the centrifuge 410 to continue running, maintain its speed, freeze its acceleration, or decelerate and stop. After receiving the control commands from the execution controller 300, the mold conveying equipment controller controls the mold conveying equipment 420 to perform mold conveying or return for re-laying. The execution controller 300 reads the equipment action completion confirmation and returns the equipment action completion confirmation to the production control host 100; the production control host 100 only updates the process completion status, centrifugation completion signal, re-laying direction, or overall process pass / fail result in the digital twin object when the equipment action completion confirmation matches the corresponding control action.

[0073] Although embodiments of this application have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of this application, and all such modifications and variations fall within the scope defined by the appended claims.

Claims

1. A fully intelligent control system for the production process of concrete poles based on digital twins, comprising a production control host, a field data acquisition device, an execution controller, and multi-station production equipment including a centrifuge and a formwork transport device, characterized in that, The production control host is used for: Create a digital twin object containing the process completion status, equipment safety interlock status and quality inspection results of each production station based on a unique batch number, and release or lock the process accordingly; The system receives the radial acceleration of the large-end support, the radial acceleration of the small-end support, the driving current, and the angular velocity of the mold from the field acquisition device. The angular position is formed by the angular velocity of the mold. The four measurement data are aligned according to the angular position within the complete rotation window of one revolution of the mold. The large-end co-rotation quantity, the small-end co-rotation quantity, and the current co-rotation quantity are extracted. The large-end co-rotation quantity and the small-end co-rotation quantity are combined into the co-rotation quantity of the two supports. The amplitude difference between the large-end co-rotation quantity and the small-end co-rotation quantity is used to form the two-end bias ratio relative to the total amplitude of the two. The current fluctuation ratio is formed by the ratio of the current co-rotation quantity to the root mean square of the current. The phase relationship between the co-rotation quantity of the two supports and the current co-rotation quantity forms the in-phase degree. The three factors form the axial co-rotation off-center load quantity that characterizes the direction and reliability of the axial off-center load. The absolute value of the axial rotation load is compared with the corresponding pole specifications and the upper limit of the centrifugation stage. The centrifuge and the moving model equipment are controlled by the actuator controller. When each centrifugation stage is completed and the absolute value of the axial rotation load does not exceed the upper limit of the release, the centrifugation completion signal is output. When all process completion statuses are met, the centrifugation completion signal has been output, and the quality inspection results are qualified, a qualified release result for the entire process is formed.

2. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 1, characterized in that, The production stations include a raw material metering station, a mixing station, a steel reinforcement cage and mold station, a material placement station, a mold closing station, a tensioning station, a centrifugal station, a steam curing station, a release station, a mold removal station, and a quality inspection station. The digital twin full-process control module calls the conventional mix ratio to control raw material metering and mixing according to the unique batch number, calls the tensioning program to control tensioning, calls the centrifugal speed program to control centrifugation, calls the steam curing program to control steam curing, and calls the quality inspection items to control quality inspection. It writes each control command and the corresponding process completion status into the digital twin object. When the mold entry quality, tension force, and tension elongation are within their respective preset process allowable ranges, the mold closing signal is satisfied, and the equipment safety interlock status is normal, the digital twin full-process control module outputs a centrifugal station release signal and controls the centrifugal station to start according to the centrifugal station release signal.

3. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 2, characterized in that, The on-site data acquisition device includes a large-end radial acceleration acquisition component located at a support vibration measurement point near the large end of the mold, a small-end radial acceleration acquisition component located at a support vibration measurement point near the small end of the mold, a frequency converter current sampling channel, and a speed encoder, which are used to acquire the large-end support radial acceleration, the small-end support radial acceleration, the drive current, and the mold angular velocity, respectively. The execution controller includes a centrifuge controller for controlling the centrifuge and a mold moving equipment controller for controlling the mold moving equipment. The centrifuge state formation module uses a unified clock to add timestamps to the four measurement data and pairs the four measurement data at the same sampling time according to the timestamps and the angular position. When the process completion status of the upstream production station is not met, any measurement data cannot be acquired, or the equipment safety interlock status is abnormal, the digital twin full-process control module prohibits the centrifuge controller from starting the centrifuge.

4. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 3, characterized in that, The centrifugal state forming module forms the large-end rotation amount and the small-end rotation amount at the fundamental frequency of mold rotation based on the radial acceleration of the large-end support and the radial acceleration of the small-end support within the same complete rotation window. After removing the average value of the driving current within the complete rotation window from the driving current, the module forms the current rotation amount at the fundamental frequency of mold rotation. It also obtains the root mean square of the current within the complete rotation window and combines the large-end rotation amount and the small-end rotation amount into the combined rotation amount of the two-end supports. When any of the normalized references required to form the bias ratio at both ends, the current fluctuation ratio, or the in-phase degree is zero and the corresponding parameters cannot be formed, the corresponding complete rotation window is marked as having no effective excitation and is excluded from the release judgment.

5. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 4, characterized in that, During the low-speed phase of the centrifugation speed program, if the absolute value of the axial co-rotation off-center load in two consecutive complete rotation windows does not exceed the release limit, the centrifugation program control module controls the centrifuge controller to continue executing the centrifugation speed program; if the absolute value of the axial co-rotation off-center load in any complete rotation window exceeds the release limit, the speed increase is paused and the current low speed is maintained to regenerate the axial co-rotation off-center load; if the absolute value of the axial co-rotation off-center load still exceeds the release limit after maintaining the current low speed, the centrifuge controller is controlled to execute a safety deceleration program to decelerate the centrifuge to a stop.

6. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 5, characterized in that, When the axial rotational offset load is zero, the centrifugal program control module does not generate the re-laying direction, and re-generates the axial rotational offset load in the next complete rotation window. When the absolute value of the axial rotational offset load still exceeds the release limit after maintaining the current low speed and the centrifuge has decelerated to a stop, the centrifugal program control module determines the re-laying direction as the large end re-laying direction when the axial rotational offset load is greater than zero, and determines the re-laying direction as the small end re-laying direction when the axial rotational offset load is less than zero. The module then controls the mold-moving equipment controller to send the mold back to the laying station for re-flattening according to the re-laying direction.

7. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 5, characterized in that, During the medium-speed or high-speed phase of the centrifugation speed program, the centrifugation program control module generates the axial co-rotation off-center load for each complete rotation window, and freezes the speed increase when the absolute value of the axial co-rotation off-center load exceeds the release limit, until the absolute value of the axial co-rotation off-center load in two consecutive complete rotation windows recovers to not exceed the release limit, and then continues to execute the centrifugation speed program; when all centrifugation phases are completed and the absolute value of the axial co-rotation off-center load does not exceed the corresponding release limit, the centrifugation completion signal is output.

8. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 7, characterized in that, After the completion status of the steam curing station, the tensioning station, and the demolding station is met, the digital twin full-process control module controls the quality inspection station to acquire the external dimensions, surface defects, and specimen strength. The external dimensions consist of the pole length, the large end diameter, and the small end diameter. The surface defects consist of crack detection results, exposed reinforcement detection results, and missing parts detection results. The quality inspection station compares the pole length, the large end diameter, the small end diameter, the crack detection results, the exposed reinforcement detection results, the missing parts detection results, and the specimen strength with their respective preset quality inspection allowable ranges. Only when all comparison results are within the corresponding preset quality inspection allowable ranges are qualified quality inspection results generated, and the quality inspection results are written into the digital twin object.

9. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 1, characterized in that, The production control host stores a release limit lookup table, and each entry in the release limit lookup table includes the corresponding pole specifications, centrifugation stage and a unique pre-configured release limit. The digital twin full-process control module uses existing production batches where the process completion status of each production station is met, the quality inspection results are qualified, and no equipment protection shutdown occurs as calibration samples for the release upper limit, and writes the calibrated release upper limit into the corresponding table entry; the centrifugation program control module obtains the release upper limit from the release upper limit lookup table according to the pole specifications of the current production batch and the current centrifugation stage.

10. The intelligent control system for the entire production process of concrete poles based on digital twins according to claim 2, characterized in that, When the completion status of the process at the current production station is not yet met, the digital twin full-process control module locks the production station following the current production station; when the safety interlock status of any device is abnormal, the production station to which the device belongs and the production stations following it are locked; when the quality inspection result is unqualified, the quality inspection station is locked; when the current production batch has not yet formed the full-process qualified release result, the next production batch is prohibited from entering the raw material metering station, and the prohibition status for the next production batch is lifted after the current production batch forms the full-process qualified release result.

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