An active demolding device for potassium superoxide tabletting

Abstract

The present application relates to the technical field of potassium superoxide tabletting production, and discloses an active demolding intelligent control device for potassium superoxide tabletting, which comprises a tabletting machine rack, a die disc arranged on the tabletting machine rack, and a pair of upper and lower punch bodies arranged in cooperation, the die disc is provided with die holes for accommodating materials and pressing into potassium superoxide tablets; the device further comprises an energy excitation module, a bionic function interface module, a wireless energy and signal transmission module, and an intelligent monitoring and closed-loop solution system. The axial ultrahigh frequency micro-amplitude reciprocating mechanical vibration generated by the piezoelectric ceramic actuator array integrated in the lower punch body, combined with the surface carefully matched laser micro-pit array or low surface energy doped ceramic coating, forcibly triggers the stress relaxation of the micro contact surface and excites the high-pressure laminar interface gas film layer in the demolding transient state, which physically destroys the bonding basis of potassium superoxide and the side wall and bottom of the die.

Description

Technical Field

[0001] This invention relates to the field of potassium superoxide tablet production technology, specifically to an active demolding device for potassium superoxide tablet production. Background Technology

[0002] Potassium superoxide, as a highly efficient solid chemical oxygen source, has irreplaceable key application value in closed special environments such as emergency rescue respiratory systems, gas masks, submarines, and spacecraft life support engineering. In practical use, it usually needs to be compressed under high pressure into hard tablets with specific geometric dimensions, high mechanical strength, and high density.

[0003] However, potassium superoxide powder has extremely harsh and unique physicochemical properties, which pose a great technical challenge to the industrial high-efficiency tableting: on the one hand, it is extremely hygroscopic and easily absorbs trace amounts of moisture from the ambient air, causing deliquescence on the mold surface and forming a highly viscous alkaline hydrate adhesive layer; on the other hand, it has an extremely high tendency to adhere to crystals. Under the static mechanical high pressure of hundreds of megapascals in the tablet press, it is very easy to form lattice-level mechanical interlocking, van der Waals physical adsorption, and solid-phase sintering with the working surface of the metal punch tip and the inner wall of the mold hole, resulting in severe interfacial adhesion during the demolding stage. Current mainstream demolding methods have significant limitations that cannot be overcome: First, while exogenous chemical lubricants widely used in the traditional tableting industry can alleviate sticking to the mold to some extent, the introduction of such chemical impurities severely degrades the oxygen release rate of potassium superoxide, greatly reducing its cleanliness and purity. This is absolutely unacceptable for aerospace-grade and medical emergency-grade life support products and does not conform to the modern industrial trend of clean and green production. Second, if no lubricant is used and the tableting machine's downward punch is increased to forcefully eject the tablets, excessive friction can easily lead to microcracks, missing corners, edge delamination, or even overall rigid fracture within the formed tablets, resulting in a low yield. Extremely low and huge transient shear stress will accelerate the severe wear of expensive molds and reduce the service life of the equipment; thirdly, during the operation of modern high-speed rotary tablet presses, the lower punch is in a composite station state of high-speed circular revolution, rotation and multi-degree-of-freedom up-and-down reciprocating linear motion. Traditional wired power transmission and signal interaction mechanisms are prone to slip ring wear, wire breakage, contact sparking and signal distortion noise in the environment of severe vibration, strong friction and strong alkaline corrosive dust. This makes it impossible to perform safe, continuous and accurate time-sequential high-power closed-loop control of the built-in actuators in the high-speed rotation state, and lacks an effective interface demolding state self-sensing and dynamic frequency tracking anti-sticking compensation control mechanism. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an active demolding device for potassium superoxide tablets, which can improve the integrity rate of finished potassium superoxide tablets.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an active demolding intelligent control device for potassium superoxide tableting, comprising: a tableting machine frame, a mold plate disposed on the tableting machine frame, and a pair of mating upper and lower punches, wherein the mold plate has die holes for receiving materials and pressing them into potassium superoxide tablets; the device further comprises: An energy excitation module is integrated into a lower punch mounting slot inside the lower punch body. It is used to generate and transmit high-frequency micro-amplitude mechanical vibration energy to the mold-material interface at the moment of demolding. The energy excitation module is a piezoelectric ceramic actuator array, which is fixed in the lower punch mounting slot through an insulating encapsulation layer. A biomimetic functional interface module is set on the top working surface of the lower punch body, the upper punch working surface of the upper punch of the pressing plate, and the inner wall of the die hole. Its surface has a micro-nano morphology that reduces the contact area with the material. A wireless power and signal transmission module is used for contactless power supply to the interior of the lower punch body and transmission of high-frequency timing pulse control signals; and The intelligent monitoring and closed-loop calculation system includes a drive control box mounted on the tablet press frame, a multi-dimensional sensor network and a closed-loop control calculation module connected to the drive control box. The closed-loop control calculation module adjusts the vibration output parameters of the energy excitation module in real time based on the dynamic characteristics collected by the multi-dimensional sensor network.

[0006] Preferably, the multi-dimensional sensor network includes a temperature monitoring probe embedded inside the lower punch body, a pressure sensor disposed at the bottom of the lower punch body, a position displacement sensor disposed on one side of the tablet press frame to monitor the lower punch stroke, and an acoustic sensor disposed at the edge of the mold plate to collect the microscopic acoustic features of demolding.

[0007] Preferably, the drive control box integrates a signal generator, a power amplifier module, and a data acquisition card; the data acquisition card is used to acquire the electrical signals of the pressure sensor, displacement sensor, temperature monitoring probe, and acoustic sensor in real time, and transmit them to the closed-loop control calculation module. The closed-loop control calculation module calculates the optimal excitation frequency and pulse width based on the real-time demolding resistance curve, and controls the signal generator and power amplifier module to output the corresponding electrical pulses.

[0008] Preferably, the outer peripheral surface of the lower punch body is provided with a rotating electrical annular groove for wiring, and multiple radial heat sinks are integrated on the outer wall of the lower punch body to dissipate the Joule heat generated by the piezoelectric ceramic actuator array during long-term operation; a sealing ring is provided at the opening end of the lower punch mounting groove, and an elastic decoupling ring is sandwiched between the piezoelectric ceramic actuator array and the force-bearing surface of the lower punch body to block the rigid transmission of ultra-high frequency vibration to the frame bearing.

[0009] Preferably, the wireless power and signal transmission module is an electromagnetic induction coupling structure, which includes a fixed transmitting unit rigidly fixed at the demolding station of the tablet press frame and a rotating receiving unit that rotates synchronously with the lower punch body; the fixed transmitting unit includes a first resonant coil, and the rotating receiving unit includes a second resonant coil opposite to and magnetically coupled to the first resonant coil; the circuit terminals of both the fixed transmitting unit and the rotating receiving unit are connected to an impedance matching network to maintain high-efficiency resonance under high-speed rotating variable gap conditions.

[0010] Preferably, the bottom end of the lower punch body is also provided with a conductive slider channel that is connected to the grounding end of the tablet press frame, so as to conduct away the electrostatic charge generated by the high-speed friction of potassium superoxide powder.

[0011] Preferably, the biomimetic functional interface module is a substrate micro-nano composite structure layer formed directly on the surface of the punch body and the die hole substrate by laser micro-nano processing or plasma etching technology. The structure layer has intersecting laser micro-pits with an average period of 30μm-80μm and a depth of 15μm-35μm.

[0012] Preferably, the biomimetic functional interface module is a low surface energy ceramic coating composited onto the surface of a metal substrate by physical vapor deposition or thermal spraying. The low surface energy ceramic coating is a diamond-like carbon coating or a boron nitride ceramic coating, with micro- and nano-morphological distributions on its surface and nanoparticle inclusions doped in the composite lattice inside the coating, thereby exhibiting a surface tension of no more than 25 mN / m on a macroscopic scale.

[0013] Preferably, the closed-loop control calculation module controls the piezoelectric ceramic actuator array to generate vibrations with an amplitude of 2μm-8μm, a vibration frequency of 25kHz-50kHz, and a continuous vibration time of 50ms-200ms at the moment of demolding; and during the vibration process, the high-frequency vibration excites a laminar interfacial gas film layer in the demolding gap between the surface micro-nano morphology and the potassium superoxide tablet to generate a transient repulsion effect.

[0014] Preferably, the device further includes an ejection auxiliary link that works in conjunction with the lower punch body. When the sudden peak demolding force detected by the pressure sensor exceeds a preset safety threshold, the closed-loop control calculation module triggers the drive control box to perform frequency sweep and frequency tracking control, and at the same time adjusts the mechanical compensation thrust of the ejection auxiliary link to prevent the potassium superoxide tablets from breaking.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This automotive bracket mounting auxiliary equipment achieves a revolutionary mechanism for active, non-destructive demolding through a deep synergy of wave dynamics and multi-scale surface bionics. It utilizes axial ultra-high frequency micro-amplitude reciprocating mechanical vibration generated by an integrated piezoelectric ceramic actuator array within the lower punch, combined with a carefully tuned laser micro-pit array or low surface energy doped ceramic coating. During demolding, it forcibly induces stress relaxation at the microscopic contact surface and excites a high-pressure laminar interfacial gas film layer. This physically and completely destroys the bonding foundation between potassium superoxide and the mold sidewalls and bottom, eliminating the need for any external chemical lubricants throughout the process. The lubricant fundamentally eliminates impurity contamination and oxygen passivation of high-purity materials, ensuring the absolute cleanliness and core quality of emergency aviation-grade chemical oxygen sources. Secondly, the system creatively introduces a wireless energy and signal transmission module based on near-field electromagnetic induction coupling and a high-order resonant impedance matching network. This enables the safe and stable injection of non-contact, frictionless, high-power, high-voltage sequential electrical pulses into the built-in actuator array during high-speed rotation and compound reciprocating linear displacement. This completely overcomes the problems of traditional wired contact slip rings being prone to wear and sparking in complex multi-axis linkages and strongly alkaline corrosive dust environments. This invention addresses common industrial problems such as wire breakage and strong signal attenuation. Furthermore, it constructs a multi-dimensional intelligent sensor network consisting of pressure, displacement, temperature, and high-frequency acoustic emission sensors. Combined with a closed-loop processor within the drive control box, this endows the system with self-sensing and self-diagnostic capabilities under high-speed continuous tableting conditions. It can not only online invert the microscopic acoustic characteristics of demolding and peeling, but also adaptively trigger electrical-grade frequency tracking control when facing extreme material sticking to the mold. It also real-time links with the bottom mechanical-grade rigid anti-fracture ejection auxiliary linkage to apply smooth dynamic mechanical thrust compensation, eliminating… In addition to the rigid impact of traditional hard-top demolding, the integrity rate of potassium superoxide tablets is increased to almost 100%. Finally, the core execution, sensing and thermal management components are highly integrated and packaged in the lower punch body and frame, which requires minimal changes to the main transmission and macroscopic load-bearing topology of the existing rotary tablet press. It has extremely strong convenience for industrial upgrades that can be installed and used immediately. At the same time, due to the extrusion force of the demolding mechanism being reduced by several times, the wear and heat generation of the inner wall of the die hole and the punch are reduced, which greatly extends the continuous safe service life of the expensive core mold and the tablet press equipment. Attached Figure Description

[0016] Figure 1 This is a three-dimensional structural diagram of the entire invention; Figure 2 This is a three-dimensional structural diagram of the entire invention from another angle; Figure 3 This is a front view of the entire invention; Figure 4 This is a cross-sectional view of the entire invention; Figure 5 This is a three-dimensional structural diagram of the lower punch body of the present invention; Figure 6 This is a three-dimensional structural diagram of the drive control box of the present invention; Figure 7 This is a cross-sectional view of the lower punch body of the present invention; Figure 8 This is a schematic diagram of the three-dimensional structure of the low surface energy ceramic coating and its surface micro / nano morphology of the present invention. Figure 9 This is a three-dimensional structural diagram of the substrate micro-nano composite layer and the laser micro-pit of the present invention.

[0017] In the diagram: 1. Lower punch body; 2. Piezoelectric ceramic actuator array; 3. Insulating encapsulation layer; 4. Fixed transmitting unit; 5. Tableting machine frame; 6. Rotating receiving unit; 7. First resonant coil; 8. Second resonant coil; 9. Substrate micro / nano composite structure layer; 10. Low surface energy ceramic coating; 11. Surface micro / nano morphology; 12. Die hole; 13. Potassium superoxide tablet; 14. Tableting machine upper punch; 15. Die plate; 16. Pressure sensor; 17. Displacement sensor; 18. Drive control box; 19. Signal generator; 20. Power amplifier module; 21. Rotary electrical annular groove; 22. Radial heat sink; 23. Temperature monitoring probe; 24. Impedance matching network; 25. Conductive slider channel; 26. Upper punch working surface; 27. Lower punch mounting groove; 28. Sealing ring; 29. ​​Elastic decoupling ring; 30. Laser micro-pit; 31. Nanoparticle inclusions; 32. Closed-loop control calculation module; 33. Acoustic sensor; 34. Data acquisition card. Detailed Implementation

[0018] The technical solutions 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.

[0019] Please see Figures 1 to 9This invention provides an active demolding device for potassium superoxide tableting. Referring to the overall topology, the main mechanical frame of the device is supported by a high-rigidity tablet press frame 5, which is integrally cast from ductile iron, exhibiting excellent vibration resistance and mechanical damping characteristics. A drive spindle is positioned on the central axis of the tablet press frame 5, driving a high-precision mold disk 15 in continuous high-speed rotation. The mold disk 15 is typically made of high-quality alloy tool steel through cryogenic treatment, and has a plurality of symmetrically spaced and equally spaced die holes 12 for accommodating materials and for powder forming. The inner walls of the die holes 12 are finely ground and polished to control their geometric dimensional tolerances within the micrometer range.

[0020] Corresponding to the die hole 12 on the die plate 15, the device is equipped with a paired upper punch 14 and a lower punch body 1 that reciprocate linearly in the vertical direction. The upper punch 14 is located directly above the die plate 15, and its bottom end has an upper punch working surface 26 for directly contacting and pressing the material. The lower punch body 1 is assembled below the die plate 15 via upper and lower guide rails and a punch rod seat, and its top end extends directly into the die hole 12. The lower punch body 1 has a stepped cylindrical structure. In order to meet the requirements of attenuation-free transmission of ultra-high frequency reciprocating mechanical waves and long-term resistance to impact compressive stress of up to hundreds of megapascals, the lower punch body 1 is preferably made of ultra-high strength powder metallurgy hard alloy or high-toughness special steel.

[0021] To embed an energy excitation source without compromising the macroscopic mechanical rigidity of the lower punch body 1, a lower punch mounting groove 27 is precisely formed inside the lower punch body 1 along its axial direction. This lower punch mounting groove 27 is preferably a cylindrical blind hole extending vertically upwards from the bottom surface of the lower punch body 1. The top of this blind hole terminates at a specific distance from the uppermost surface of the lower punch. This specific distance is determined through rigorous finite element analysis of wave dynamics to ensure that the high-frequency mechanical wave reaches the top surface precisely at the antinode, thereby maximizing the amplitude output. A sealing ring 28 is specially provided at the opening end of the lower punch mounting groove 27. This sealing ring 28 is typically made of fluororubber or perfluoroether rubber, which is resistant to strong alkalis, high temperatures, and oxidation. Combined with a precise groove design, it aims to completely isolate extremely small amounts of potassium superoxide alkaline dust and trace amounts of water vapor from the external environment, preventing them from entering the lower punch mounting groove 27.

[0022] An elastic decoupling ring 29 is also clamped at the bottom of the lower punch mounting groove 27. The elastic decoupling ring 29 is made of ultra-high molecular weight polyethylene or special spring steel gasket with specific dynamic stiffness, and is clamped between the actuating element and the force-bearing surface of the bottom of the lower punch body 1 groove. The physical significance of the elastic decoupling ring 29 is that it exhibits high rigidity in the high-pressure stage of low-frequency and static tableting, and can normally transmit the rigid pressure of the main pressure roller; while in the high-frequency demolding vibration stage, it exhibits high impedance, which can effectively block the transmission of ultra-high frequency mechanical vibration to the bottom of the lower punch, and prevent mechanical vibration from scattering to the tablet press frame 5 and the main shaft bearing, thereby rigidly transmitting the vibration energy upward to the demolding interface.

[0023] The core power source of this invention—the energy excitation module—is a highly efficient electro-mechanical energy conversion unit, fully integrated into the lower punch mounting slot 27 inside the lower punch body 1. Specifically, this energy excitation module employs a piezoelectric ceramic actuator array 2 based on the inverse piezoelectric effect. The piezoelectric ceramic actuator array 2 is composed of a plurality of bipolar multilayer piezoelectric ceramic wafers mechanically connected in series and electrically connected in parallel along the axial direction. This stacked structure composed of multilayer wafers can achieve micron-level dynamic displacement output at a relatively low driving voltage, greatly reducing the insulation withstand voltage requirements of the system for high-voltage wireless transmission components.

[0024] To ensure the electrical safety of the piezoelectric ceramic actuator array 2 within the dense metal cavity of the lower punch body 1, the entire array is completely encapsulated by an insulating encapsulation layer 3. This insulating encapsulation layer 3 is formed by vacuum potting of a special modified epoxy resin with extremely high thermal conductivity and dielectric strength. The insulating encapsulation layer 3 not only firmly anchors and fixes the piezoelectric ceramic actuator array 2 within the lower punch mounting groove 27, but also plays a dual crucial role: firstly, it achieves absolute electrical insulation between the high-voltage electrodes of the piezoelectric ceramic and the hard alloy lower punch body 1; secondly, it establishes an efficient radial heat conduction channel.

[0025] Because the piezoelectric ceramic actuator array 2 inevitably generates Joule heating and frictional heating due to its internal dielectric and mechanical losses during high-frequency, continuous, high-power reciprocating operation, once the internal temperature of the crystal stack exceeds its Curie point, the piezoelectric material will undergo irreversible thermal depolarization and completely fail. To achieve precise thermal management, a high-sensitivity temperature monitoring probe 23 is embedded inside the lower punch body 1, close to the outer side of the insulating encapsulation layer 3. Simultaneously, multiple outwardly radiating radial heat sinks 22 are integrally machined or thermally interference-fitted onto the middle or lower outer wall of the lower punch body 1 exposed to air. These radial heat sinks 22 are made of high-thermal-conductivity copper or aerospace-grade aluminum and employ a multi-layer laminar flow resistance optimized structure. When the lower punch rotates at high speed, it can generate a strong convective heat transfer effect, rapidly dissipating the heat conducted internally into the flowing air.

[0026] Furthermore, to establish an external electrostatic discharge channel, the potassium superoxide powder, due to the intense friction with the metal mold during high-speed filling and pressing, easily accumulates tens of thousands of volts of static charge at the tip of the lower punch. This can easily break down the internal piezoelectric insulation layer and even cause localized chemical deterioration of the potassium superoxide. The present invention provides an axial or radial conductive slider channel 25 extending from the bottom end of the lower punch body 1. This conductive slider channel 25 is internally equipped with a highly conductive graphite-copper-based slider and a pre-tensioning spring. The outer end face of the slider is connected to the rigid grounding terminal of the tablet press frame 5, thereby constructing a low-impedance electrostatic discharge circuit, ensuring that the lower punch body 1 is always in a zero-potential state.

[0027] During the operation of the rotary multi-station tablet press, the lower punch body 1 not only revolves at high speed with the main shaft, but also generates complex rotation and reciprocating linear displacement through the guide rail at the bottom. Traditional slip rings or drag chain cables, under such high-frequency, high-voltage, and multi-degree-of-freedom complex motion, will experience wear, contact sparking, or wire breakage due to mechanical fatigue within a short period, introducing severe electromagnetic noise. Therefore, this invention employs advanced non-contact wireless power and signal transmission modules throughout.

[0028] Referring to the wireless transmission topology, the core of this module is based on a near-field wireless electromagnetic induction coupling architecture, including a set of spatially separated, non-contactly coupled fixed transmitting units 4 and rotating receiving units 6. The fixed transmitting unit 4 is rigidly fixed to the tablet press frame 5 by a high-strength insulating rigid bracket, and its spatial position is precisely focused directly below the demolding station of the tablet press trajectory. The fixed transmitting unit 4 internally encapsulates a first resonant coil 7 precisely wound from Litz wire, and a toroidal manganese-zinc ferrite core with high permeability and low high-frequency loss.

[0029] Correspondingly, the rotating receiving unit 6 is integrated and mounted on the base or lower outer periphery of the lower punch body 1, and rotates synchronously at high speed with the lower punch body 1. The rotating receiving unit 6 contains a second resonant coil 8 coaxially opposed to the first resonant coil 7 and maintaining a specific air gap in space. To introduce high-voltage pulses and high-frequency energy into the lower punch without loss, a rotating electrical annular groove 21 for wiring is formed on the outer peripheral surface of the lower punch body 1. Through the fine, high-temperature resistant insulated wires laid within this rotating electrical annular groove 21, the output terminal of the second resonant coil 8 is electrically connected to the input electrode of the internal piezoelectric ceramic actuator array 2.

[0030] Considering that during the operation of the tablet press, due to mechanical tolerances and vibrations, the air gap and relative alignment area between the first resonant coil 7 and the second resonant coil 8 will experience dynamic slight drift, which will cause changes in the system's mutual inductance coefficient, leading to drastic fluctuations in transmission efficiency. To solve this industry problem, this invention seamlessly connects a high-order dynamic impedance matching network 24 in series or parallel at the circuit terminals of both the fixed transmitting unit 4 and the rotating receiving unit 6. The impedance matching network 24 is composed of a combination of high-value miniature inductors and high-voltage ceramic capacitors. By adjusting the resonant point, the system maintains a highly resonant state throughout the entire demolding time window, ensuring stable energy transmission efficiency.

[0031] Another key inventive point of this invention is that the high-frequency micro-amplitude vibrations generated by the energy excitation module are insufficient to completely destroy the strong adhesion of potassium superoxide. Therefore, it is necessary to introduce microscopic geometric morphology at the interface and utilize the synergistic effect of wave dynamics and surface physics to achieve zero-resistance demolding. To this end, this invention designs two independent, parallel, and subordinate technical routes.

[0032] In this technical approach, no foreign material components are introduced, thereby ensuring that the mold surface completely maintains its original high-strength mechanical properties. Specifically, referring to the microstructure, a substrate micro-nano composite structure layer 9 integrally formed with the substrate is directly ablated on the top working surface of the lower punch body 1, the upper punch working surface 26 of the upper punch 14 of the tablet press, and the entire inner wall substrate surface of the die hole 12 by ultra-short pulse laser micro-nano processing such as femtosecond laser or picosecond laser or reactive plasma etching technology.

[0033] Specifically, the substrate micro-nano composite structure layer 9 is microscopically composed of an array of multiple interlaced, regularly arranged laser micro-pits 30 or micro-stripes. On the inner wall and edges of each laser micro-pit 30, due to the secondary recrystallization effect of laser thermal ablation, uniform nanoscale protrusions are naturally distributed. This multi-level composite structure, consisting of large pits at the tens of micrometer scale and small protrusions at the hundreds of nanometer scale, perfectly simulates the superhydrophobic biomimetic principle of the surface of a lotus leaf in nature. When highly viscous potassium superoxide powder is filled and compressed under macroscopic high pressure, the powder crystals, limited by the yield limit of their solid phase, cannot be completely fluidized and squeezed into the interior of these fine laser micro-pits 30, thus retaining a large number of microscopic air bubbles inside the pits. This drastically reduces the actual solid-solid contact area between the potassium superoxide powder and the mold metal, fundamentally weakening the initial van der Waals force consolidation basis.

[0034] As a parallel second implementation, in order to further improve the chemical inertness of the mold surface and give it extremely low dispersive force components, a high-density, low-surface-energy ceramic coating 10 can be compositely superimposed on the top working surface of the lower punch body 1, the upper punch working surface 26, and the metal substrate surface of the die hole 12 by physical vapor deposition or supersonic plasma thermal spraying process.

[0035] The substrate material of the low surface energy ceramic coating 10 is preferably a diamond-like carbon coating or an amorphous boron nitride ceramic coating with ultra-high hardness, low coefficient of friction, and excellent chemical inertness. Specifically, on the macroscopic surface of the low surface energy ceramic coating 10, by adjusting the bias voltage of the deposited vapor phase and the flow field of the channel, it naturally grows and distributes surface micro-nano morphologies 11 with specific roughness undulations. More importantly, within the internal composite lattice of the ceramic coating, a specific proportion of nanoparticle inclusions 31 are unevenly doped. These nanoparticle inclusions 31 are preferably nano-sized polytetrafluoroethylene particles, nano-fluorinated carbon, or nano-zirconia particles. The introduction of these nanoparticle inclusions 31 breaks the continuity of the original ceramic lattice, resulting in an extremely excellent superoleophobic and superhydrophobic property on a macroscopic scale. Its measured surface tension is extremely low, strictly controlled within the range of no more than 25 mN / m. Potassium superoxide powder can hardly establish effective physicochemical adsorption bonds on the surface of this coating, significantly reducing the floor of the demolding resistance.

[0036] When the energy excitation module applies high-frequency mechanical vibration, both the aforementioned laser micro-pits 30 and the surface micro / nano morphology 11 of the coating will undergo high-frequency microscopic peeling and displacement with the tablet contact surface. Under the disturbance of high-speed reciprocating shear waves, the microscopic air bubbles that were originally left in the micro-pits or morphology gaps undergo intense acoustic cavitation and compression, rapidly diffusing and connecting in a very short time. Finally, a continuous high-pressure interfacial gas film layer with laminar flow characteristics is forcibly generated in the interface gap between the potassium superoxide tablet 13 and the entire mold. This transiently formed interfacial gas film layer plays a near-perfect air cushion suspension and isolation effect at the microscopic level, causing the peeling torque between the potassium superoxide tablet 13 and the mold to instantly return to zero.

[0037] In order to transform the aforementioned mechanical and material components into an inventive device with adaptive adjustment capabilities, this invention fully deploys an intelligent closed-loop monitoring system consisting of a multi-dimensional sensor network and an external drive control box 18.

[0038] The multidimensional sensor network spans multiple static and dynamic dimensions, and its specific assembly layout is as follows: Pressure sensor 16: It adopts a high-frequency response quartz crystal piezoelectric force sensor, which is rigidly installed between the bottom plane of the lower punch body 1 and the lower mechanical push rod. It is used to capture the ultra-high punching pressure that the lower punch bears in real time during the pressing stage with a high sampling rate. More importantly, it is used to accurately capture the transient reaction force encountered by the lower punch when it moves upward at the moment of demolding.

[0039] Displacement sensor 17: A non-contact, high-precision, high-frequency laser triangular reflection displacement sensor or grating ruler is fixedly installed on one side of the tablet press frame 5. Its laser beam is precisely aligned with the lower edge of the lower punch body 1 to monitor the three-dimensional absolute coordinates of the vertical stroke of the lower punch body 1 over time in real time.

[0040] Temperature monitoring probe 23: As mentioned above, it is embedded in the lower punch mounting slot 27 and provides real-time feedback on the core operating temperature of the piezoelectric crystal stack.

[0041] Acoustic sensor 33: A high-frequency acoustic emission sensor is used, and its base is fixedly mounted on the frame on the edge of the mold plate 15 or the side of the demolding station by magnetic adsorption or rigid thread attachment. The detection frequency band of the acoustic sensor 33 is specifically designed to collect the characteristic microscopic acoustic peeling emission signals generated and radiated outward during the moment of demolding and peeling of potassium superoxide solid wafers, when the crystal micro-fractures and the contact surfaces detach.

[0042] These high-frequency, weak sensor electrical signals are collected and transmitted via shielded cables to the drive control box 18 located outside the rack. The core of the drive control box 18 is integrated with a multi-channel high-speed data acquisition card 34, a micro signal generator 19, a wideband power amplifier module 20, and a high-performance main control central processing unit—a closed-loop control calculation module 32. The data acquisition card 34 is responsible for synchronously and accurately converting the input pressure, displacement, and acoustic signals into digital signals. The closed-loop control calculation module 32 runs an advanced adaptive control algorithm, capable of performing online differential calculations on the input demolding resistance curve to calculate the maximum transient demolding peak force. Simultaneously, it performs real-time short-time Fourier transform or wavelet time-frequency inversion on the acoustic emission signals acquired by the acoustic sensor 33 to identify the characteristic acoustic emission energy spectrum peaks representing successful overall tablet removal.

[0043] In certain extreme environments, the adhesion of potassium superoxide may undergo a sudden and abrupt change, at which point conventional single-frequency vibration of piezoelectric ceramics alone may not be sufficient to achieve complete demolding. To provide a final, absolute safety barrier for the high-value potassium superoxide tablets 13, this invention also introduces a mechanically grade, rigid, anti-fragmentation ejection auxiliary linkage.

[0044] The ejection auxiliary linkage (not shown) is made of high-toughness heavy-duty alloy steel, and its mechanical structure is rigidly linked to the bottom end of the lower punch body 1 through a hinge and an electro-hydraulic servo valve. In the normal demolding state, the ejection auxiliary linkage remains stationary, and the lower punch body 1 is pushed upwards solely by the preset trajectory of the mechanical cam track. However, when the transient peak demolding force detected by the pressure sensor 16 exceeds the preset safety threshold...

[0045] At this point, the closed-loop control solution module 32 will immediately activate the highest level of protective compensation control strategy with two-stage linkage: Level 1: Electrical frequency sweep and tracking control. The main control system's command signal generator 19 and power amplifier module 20 break away from the original single fixed frequency output and enter a wideband dynamic frequency sweep mode. This is because when the tablets are severely adhered to the mold, the mechanical boundary conditions and resonant frequencies of the entire punching system shift drastically. By sweeping the frequency, the new system resonance point under the current severely adhered state can be quickly found, thereby maximizing the conversion of electrical energy into vibrational destructive force to forcibly shatter the microscopic adhesion sites.

[0046] Level Two: Precise Compensation of Mechanical Thrust. While performing frequency sweeping and tracking, the closed-loop control calculation module 32 outputs a high-precision current control signal to the bottom electro-hydraulic servo valve, activating the ejection auxiliary linkage. The ejection auxiliary linkage, moving from bottom to top, directly and smoothly applies a dynamic, smooth mechanical compensation thrust to the bottom end of the lower punch body 1. This thrust's physical curve does not contain any rigid impact; instead, it is controlled in real-time using a PID closed-loop approximation based on the difference feedback from the pressure sensor 16. By flexibly increasing the upward mechanical thrust, it assists the lower punch body 1 in rising smoothly and uniformly. This avoids the destructive pulverization of tablets caused by the transient, massive impact force resulting from the rigid cam's hard push in traditional tablet presses, ensuring that the potassium superoxide tablets 13 can still be lifted intact from the die hole 12 even under extreme sticking conditions.

[0047] A complete description of the end-to-end closed-loop dynamic interactive working principle of the device The present invention provides an active demolding intelligent control device for potassium superoxide tablets. The complete end-to-end closed-loop working principle of this device, which ultimately achieves lubricant-free, efficient, and non-destructive demolding, is described below: When the rotary tablet press starts operating, high-purity potassium superoxide powder is automatically and quantitatively filled into the die hole 12 on the rotating die disk 15 via a sealed feeder. Subsequently, the die disk 15 carries the material and rotates through the main pressure roller station. At this time, under the mechanical rigid extrusion of the upper punch working surface 26 of the upper punch 14 and the top working surface of the lower punch body 1, a static mechanical high pressure of up to 350 MPa is applied to the potassium superoxide powder inside the die hole 12, causing the powder particles to undergo solid-phase recombination and agglomeration, and compressing them into hard cylindrical potassium superoxide tablets 13 with a preset density. During this extremely high static pressure stage, the displacement sensor 17 and the pressure sensor 16 transmit the high-load tableting curve collected in real time to the closed-loop control calculation module 32 in the external drive control box 18 for dynamic backup, while the strong static charge accumulated at the top of the lower punch body 1 is continuously and safely discharged to the machine frame ground through the conductive slider channel 25, and the generated Joule heat is dissipated by convection through the radial heat sink 22.

[0048] After tableting is completed, the upper punch 14 of the tablet press is lifted upward along the mechanical track and withdrawn from the die hole 12. As the die plate 15 continues to rotate, the lower punch body 1, which contains potassium superoxide tablets 13, precisely cuts into the preset demolding position. At this instant, the closed-loop control calculation module 32 immediately issues a precise timing trigger command based on the stroke characteristics fed back by the displacement sensor 17. The signal generator 19 located in the external drive control box 18 instantly generates a high-frequency electrical signal of a specific frequency, which is linearly amplified into high-voltage pulse energy by the power amplifier module 20. This high-frequency electrical energy is injected into the first resonant coil 7 of the fixed transmitting unit 4, which is fixedly mounted on the frame, through the impedance matching network 24 at the transmitting end, thereby exciting an ultra-high frequency, high-density dynamic alternating electromagnetic field in the air gap. The second resonant coil 8 of the rotating receiving unit 6, which rotates at high speed with the lower punch body 1 through this area, receives the high-frequency pulse energy through resonant non-contact induction under the combined action of spatial magnetic field coupling and the impedance matching network 24 at the receiving end. After being processed by the internal high-speed rectification, filtering and shaping circuit, the electrical energy is instantly injected into the piezoelectric ceramic actuator array 2 encapsulated inside the lower punch mounting slot 27 through the high-temperature resistant insulated wire embedded in the rotating electrical ring groove 21.

[0049] Upon receiving the high-frequency, high-voltage electric pulse signal, the piezoelectric ceramic actuator array 2 rapidly generates axial ultra-high-frequency micro-amplitude reciprocating mechanical vibration within milliseconds due to the inverse piezoelectric effect. Because the elastic decoupling ring 29 cuts off the scattering path of the vibration to the mechanical housing base at the bottom, the high-frequency mechanical shock wave, with high energy density, penetrates axially upwards through the hard alloy column of the lower punch body 1, and is vertically applied and delivered to the top working surface and the inner wall of the die hole 12.

[0050] When this ultra-high frequency reciprocating mechanical energy is transmitted to the biomimetic functional interface module pre-arranged with laser micro-pits 30, the physical balance at the microscopic level is instantly broken. Under the combined action of high-speed reciprocating shear waves and the inertial mass of the solid tablet, microscopic high-frequency peeling and displacement occur between the potassium superoxide tablet 13, which was originally tightly bonded to the mold surface and the sidewall of the mold hole 12, and the metal substrate. This causes strong transient mechanical relaxation and breakage of the microscopic mechanical interlocking sites and van der Waals force physical bonds between the two. At the same time, the microscopic air bubbles that were originally tightly confined inside the laser micro-pits 30 undergo violent volume expansion and lateral acoustic diffusion under the intense cavitation and compression of the ultra-high frequency sound field. As a result, a continuous, uniform, high-pressure interface gas film layer with laminar flow characteristics is forcibly squeezed and generated in the contact interface gap between the top surface of the lower punch body 1, the inner wall of the mold hole 12, and the potassium superoxide tablet 13. This transiently formed interfacial gas film layer macroscopically manifests as a sharp drop in contact area and a dramatic decrease in frictional resistance, causing the potassium superoxide tablet 13 to be in a micro-suspension and peeling state, enveloped by a high-pressure air cushion.

[0051] Within a fraction of a second of the formation of the interfacial gas film layer, the standard ejection cam at the bottom of the tablet press pushes the lower punch 1 to begin a vertical upward demolding motion. Because the adhesion between the tablet's bottom and sides has been weakened by the high-frequency vibration and the gas film effect, the lower punch 1 only needs to withstand a minimal physical ejection force to slide upwards easily and smoothly. At this time, the high-frequency acoustic sensor 33, fixedly mounted on the edge of the mold plate 15, collects the weak acoustic emission signal emitted during the crystal debonding process in real time. Its characteristic energy spectrum peak is captured by the closed-loop control calculation module 32, and the algorithm determines that demolding is proceeding smoothly.

[0052] If, at this instant, the material becomes extremely sticky due to abnormal external environment, and the sudden demolding resistance detected by the pressure sensor 16 instantly exceeds the preset safety threshold within the initial few millimeters of the demolding start, the closed-loop control calculation module 32 will activate the highest level two-stage closed-loop compensation mechanism: on the one hand, it instructs the external signal generator 19 to enter a wideband fast frequency sweep mode to track the optimal resonance point of the new system under the current severe adhesion boundary conditions online, so as to maximize the amplitude output of the piezoelectric crystal stack; on the other hand, the drive control box 18 immediately activates the ejection auxiliary linkage located at the bottom of the lower punch, and provides a smooth, non-rigid impact, adjustable vertical mechanical compensation thrust to the bottom of the lower punch body 1 through the electro-hydraulic servo valve, flexibly assisting the lower punch in overcoming the transient maximum adhesion resistance.

[0053] Ultimately, under the synergistic effect of internal piezoelectric high-frequency energy excitation, surface micro-nano biomimetic morphology gas film effect, and bottom intelligent control of mechanical compensation thrust in a three-dimensional closed loop, the potassium superoxide tablets 13, which are originally prone to sticking and breaking, are perfectly, without damage, intact and smooth ejected from the die hole 12 and sent to the feeding plate for collection. Meanwhile, the entire lower punch body 1 returns downward through the guide rail and enters the next cycle of powder filling and pressing. The whole process is automated and intelligent closed-loop operation, which completely solves the problem of lubrication-free clean molding of high-risk and high-viscosity materials such as potassium superoxide.

[0054] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An intelligent control device for active demolding of potassium superoxide tablets, characterized in that, include: The device comprises a tablet press frame (5), a die plate (15) mounted on the tablet press frame (5), and a tablet press upper punch (14) and a lower punch body (1) arranged in pairs. The die plate (15) has die holes (12) for receiving materials and pressing them into potassium superoxide tablets (13). The device is characterized by further comprising: An energy excitation module is integrated in the lower punch mounting slot (27) inside the lower punch body (1) and is used to generate and transmit high-frequency micro-amplitude mechanical vibration energy to the mold-material interface at the moment of demolding. The energy excitation module is a piezoelectric ceramic actuator array (2), which is fixed in the lower punch mounting slot (27) through an insulating encapsulation layer (3). A biomimetic functional interface module is set on the top working surface of the lower punch body (1), the upper punch working surface (26) of the upper punch (14) of the tablet press, and the inner wall of the die hole (12), and its surface has a surface micro-nano morphology (11) that reduces the contact area with the material. A wireless power and signal transmission module for non-contactly supplying power to the interior of the lower punch body (1) and transmitting high-frequency timing pulse control signals; and The intelligent monitoring and closed-loop calculation system includes a drive control box (18) installed on the tablet press frame (5), and a multi-dimensional sensor network and a closed-loop control calculation module (32) connected to the drive control box (18). The closed-loop control calculation module (32) adjusts the vibration output parameters of the energy excitation module in real time according to the dynamic characteristics collected by the multi-dimensional sensor network.

2. The active demolding intelligent control device for potassium superoxide tablets according to claim 1, characterized in that: The multidimensional sensor network includes a temperature monitoring probe (23) embedded inside the lower punch body (1), a pressure sensor (16) set at the bottom of the lower punch body (1), a position displacement sensor (17) set on one side of the tablet press frame (5) to monitor the lower punch stroke, and an acoustic sensor (33) set on the edge of the mold plate (15) to collect the micro-acoustic characteristics of demolding.

3. The active demolding intelligent control device for potassium superoxide tablets according to claim 2, characterized in that: The drive control box (18) integrates a signal generator (19), a power amplifier module (20), and a data acquisition card (34); the data acquisition card (34) is used to acquire the electrical signals of the pressure sensor (16), displacement sensor (17), temperature monitoring probe (23), and acoustic sensor (33) in real time, and transmit them to the closed-loop control calculation module (32). The closed-loop control calculation module (32) calculates the optimal excitation frequency and pulse width based on the real-time demolding resistance curve, and controls the signal generator (19) and power amplifier module (20) to output the corresponding electrical pulses.

4. The active demolding intelligent control device for potassium superoxide tablets according to claim 1, characterized in that: The outer peripheral surface of the lower punch body (1) is provided with a rotating electrical ring groove (21) for wiring, and multiple radial heat sinks (22) are integrated on the outer wall of the lower punch body (1) to dissipate the Joule heat generated by the piezoelectric ceramic actuator array (2) during long-term operation; a sealing ring (28) is provided at the opening end of the lower punch mounting groove (27), and an elastic decoupling ring (29) is sandwiched between the piezoelectric ceramic actuator array (2) and the force-bearing surface of the lower punch body (1) to block the rigid transmission of ultra-high frequency vibration to the frame bearing.

5. The active demolding intelligent control device for potassium superoxide tablets according to claim 1, characterized in that: The wireless energy and signal transmission module is an electromagnetic induction coupling structure, which includes a fixed transmitting unit (4) rigidly fixed at the demolding station of the tablet press frame (5) and a rotating receiving unit (6) that rotates synchronously with the lower punch body (1); the fixed transmitting unit (4) includes a first resonant coil (7), and the rotating receiving unit (6) includes a second resonant coil (8) opposite to and magnetically coupled to the first resonant coil (7); the circuit terminals of the fixed transmitting unit (4) and the rotating receiving unit (6) are both connected to an impedance matching network (24) to maintain high-efficiency resonance under high-speed rotating variable gap conditions.

6. The active demolding intelligent control device for potassium superoxide tablets according to claim 1, characterized in that: The bottom end of the lower punch body (1) is also provided with a conductive slider channel (25) that is connected to the grounding end of the tablet press frame (5) to conduct away the electrostatic charge generated by the high-speed friction of potassium superoxide powder.

7. The active demolding intelligent control device for potassium superoxide tablets according to claim 1, characterized in that: The biomimetic functional interface module is specifically a substrate micro-nano composite structure layer (9) formed directly on the substrate surface of the punch body (1) and the die hole (12) by laser micro-nano processing or plasma etching technology. The structure layer has intersecting laser micro pits (30) with an average period of 30μm-80μm and a depth of 15μm-35μm.

8. The active demolding intelligent control device for potassium superoxide tablets according to claim 1, characterized in that: The biomimetic functional interface module is specifically a low surface energy ceramic coating (10) composited on the surface of a metal substrate by physical vapor deposition or thermal spraying. The low surface energy ceramic coating (10) is a diamond-like carbon coating or a boron nitride ceramic coating. Its surface has micro- and nano-morphological features (11), and the composite lattice inside the coating is doped with nanoparticle inclusions (31), thereby exhibiting a surface tension of no more than 25 mN / m on a macroscopic scale.

9. The active demolding intelligent control device for potassium superoxide tablets according to claim 3, characterized in that: The closed-loop control calculation module (32) controls the piezoelectric ceramic actuator array (2) to generate a vibration amplitude of 2μm - 8μm, a vibration frequency of 25kHz - 50kHz, and a continuous vibration time of 50ms - 200ms at the moment of demolding; and during the vibration process, the high-frequency vibration excites a laminar interfacial gas film layer in the demolding gap between the surface micro-nano morphology (11) and the potassium superoxide tablet (13) to generate a transient repulsion effect.

10. The active demolding intelligent control device for potassium superoxide tablets according to claim 2, characterized in that: The device also includes an ejection auxiliary link that works in conjunction with the lower punch body (1). When the sudden demolding peak force detected by the pressure sensor (16) exceeds the preset safety threshold, the closed-loop control calculation module (32) triggers the drive control box (18) to perform frequency sweep and frequency tracking control, and at the same time adjusts the mechanical compensation thrust of the ejection auxiliary link to prevent the potassium superoxide tablet (13) from breaking.

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