A method and system for managing and controlling an MES system based on lightweight manufacturing of glass containers

Abstract

The present application relates to glass container manufacturing production management and control technical field, especially to a kind of MES system management and control method and system based on glass container light weight intelligent manufacturing.The method comprises the following steps: obtaining cold end wall thickness detection device according to cavity number, and obtaining each cavity wall thickness deviation information by analysis;Total pipe pressure sensor is acquired by pressure fluctuation signal;According to wall thickness deviation information and pressure fluctuation signal, the opening phase shift of each cavity cooling air solenoid valve in forming cycle is determined;Wherein, the opening phase shift of wall thickness lower limit cavity makes the total pipe pressure value corresponding to the opening time of the cavity solenoid valve greater than the total pipe pressure value corresponding to the opening phase shift of wall thickness upper limit cavity.The present application arranges the peak-shaving of cooling air total pipe pressure fluctuation and the opening phase of each cavity on-off solenoid valve, to realize the differential distribution of cavity level cooling air volume, so as to improve the uniformity of light weight glass container wall thickness and the minimum wall thickness qualified rate.

Description

Technical Field

[0001] This invention relates to the field of glass container manufacturing production control technology, and in particular to a MES system control method and system based on lightweight intelligent manufacturing of glass containers. Background Technology

[0002] In the lightweight molding process of glass containers, the cooling airflow of each mold cavity in the forming machine has a decisive impact on the uniformity of the bottle wall thickness. The existing forming machine's cooling air system is supplied by a central duct, with each mold cavity's cooling air branch pipe only equipped with on / off solenoid valves, lacking stepless airflow adjustment capability. The MES system's control over the cooling airflow is limited to setting the total air pressure and starting / stopping the entire machine, unable to differentiate the cooling airflow of individual mold cavities based on real-time wall thickness deviations. When a mold cavity's wall thickness is too thin due to insufficient cooling, compensation can only be achieved by adjusting the total air pressure of the entire machine, but this operation simultaneously alters the cooling conditions of other normal mold cavities, further worsening wall thickness uniformity. Therefore, the existing MES system's control method cannot achieve independent adjustment of the cooling airflow at the mold cavity level, making it difficult to consistently improve the wall thickness uniformity and minimum wall thickness qualification rate of lightweight glass containers. Summary of the Invention

[0003] Therefore, it is necessary to provide a method and system for MES system management based on lightweight intelligent manufacturing of glass containers to solve at least one of the above-mentioned technical problems.

[0004] To achieve the above objectives, a MES system control method based on lightweight intelligent manufacturing of glass containers is provided. The lightweight intelligent manufacturing of glass containers includes a row-and-row machine, which has a multi-cavity cooling air system. The cooling air system includes a main pipe and cooling air branch pipes connected to each cavity. Each cooling air branch pipe is equipped with a switch-type solenoid valve, and a pressure sensor is installed on the main pipe. A cold end wall thickness detection device is also installed at the rear end of the row-and-row machine. The method includes the following steps:

[0005] Step S1: Obtain the wall thickness deviation information of each mold cavity by analyzing the cold end wall thickness detection device according to the mold cavity number; obtain the pressure fluctuation signal collected by the main pipe pressure sensor;

[0006] Step S2: Based on the wall thickness deviation information and pressure fluctuation signal, determine the opening phase offset of the cooling air solenoid valve of each mold cavity during the molding cycle; wherein, the opening phase offset of the mold cavity with lower wall thickness exceeds the limit so that the total pipe pressure value corresponding to the opening time of the solenoid valve of that mold cavity is greater than the total pipe pressure value corresponding to the opening phase offset of the mold cavity with higher wall thickness exceeds the limit, and the magnitude of the phase offset corresponds to the amplitude of the wall thickness deviation.

[0007] Step S3: Control the cooling air solenoid valves of each mold cavity to perform asynchronous switching actions according to the determined phase offset. The opening phases of each mold cavity are staggered during the molding cycle. The total pipe pressure value at the opening time of each mold cavity solenoid valve is determined by the opening phase.

[0008] Step S4: The MES system receives the cold end wall thickness detection data and updates the phase offset of the cooling air solenoid valve of each mold cavity based on the cold end wall thickness detection data.

[0009] This invention also provides a control system for a MES system based on lightweight intelligent manufacturing of glass containers, used to execute the above-described control method for the MES system based on lightweight intelligent manufacturing of glass containers. The control system for the MES system based on lightweight intelligent manufacturing of glass containers includes:

[0010] The mold cavity condition acquisition module is used to acquire the wall thickness deviation information of each mold cavity according to the mold cavity number by the cold end wall thickness detection device; and to acquire the pressure fluctuation signal collected by the main pipe pressure sensor.

[0011] The phase offset determination module is used to determine the opening phase offset of the cooling air solenoid valve of each mold cavity during the molding cycle based on the wall thickness deviation information and pressure fluctuation signal. Among them, the opening phase offset of the mold cavity with lower wall thickness limit makes the total pipe pressure value corresponding to the opening time of the solenoid valve of that mold cavity greater than the total pipe pressure value corresponding to the opening phase offset of the mold cavity with upper wall thickness limit, and the magnitude of the phase offset corresponds to the amplitude of the wall thickness deviation.

[0012] The asynchronous switch execution module is used to control the cooling air solenoid valves of each mold cavity to perform asynchronous switching actions according to a determined phase offset. The opening phases of each mold cavity are staggered during the molding cycle, and the total pipe pressure value at the opening time of each mold cavity solenoid valve is determined by the opening phase.

[0013] The phase offset update module is used by the MES system to receive cold end wall thickness detection data and update the phase offset of the cooling air solenoid valve of each mold cavity based on the cold end wall thickness detection data.

[0014] The beneficial effects of the present invention are as follows:

[0015] On the one hand, regarding the differentiated adjustment of cooling airflow at the mold cavity level, this invention uses the inherent pressure fluctuation signal of the cooling air main duct during the molding cycle as a phase control benchmark. The opening phases of the switching solenoid valves for each mold cavity are staggered using the MES system. The opening time of the mold cavity exceeding the wall thickness limit is determined near the pressure peak of the main duct, allowing this mold cavity to obtain a larger cooling airflow per unit time; the opening time of the mold cavity exceeding the wall thickness limit is determined near the pressure trough of the main duct, allowing this mold cavity to obtain a smaller cooling airflow. Simultaneously, because the opening phases of the solenoid valves for each mold cavity are staggered, the large fluctuations in the main duct pressure caused by synchronous switching are effectively suppressed, improving the pressure stability of the cooling air duct network. The cooling intensity of each mold cavity precisely corresponds to its wall thickness deviation, avoiding the cascading interference of uniform adjustment of the entire machine on the normal mold cavity cooling conditions.

[0016] On the other hand, regarding cavity-level closed-loop adaptive control, this invention uses the consistency between the direction of the cold-end wall thickness deviation change rate and the current phase offset adjustment direction as the update criterion. Phase offset correction is only applied to cavities where the wall thickness deviation continuously expands in the same direction and the magnitude of change increases, while the current offset remains unchanged for cavities that have converged or are experiencing random fluctuations. This update strategy avoids system oscillations caused by frequent adjustments, allowing the phase offset of each cavity to gradually approach a stable value that matches the actual cooling requirements of each cavity during continuous batch production. This promotes the continuous convergence of wall thickness uniformity and minimum wall thickness qualification rate in lightweight glass containers with each batch iteration. Attached Figure Description

[0017] Figure 1 This is a flowchart illustrating the steps of a MES system control method based on lightweight intelligent manufacturing of glass containers.

[0018] Figure 2 This is a schematic diagram showing the connection relationship of the cold end wall thickness detection device in the lightweight intelligent manufacturing of glass containers of the present invention;

[0019] Figure 3 This is a diagram of the operating interface of the MES system for lightweight intelligent manufacturing of glass containers according to the present invention.

[0020] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0021] The technical method of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0022] Furthermore, the accompanying drawings are merely illustrative of the invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted. Some block diagrams shown in the drawings are functional entities and do not necessarily correspond to physically or logically independent entities. These functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor methods and / or microcontroller methods.

[0023] It should be understood that although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are used merely to distinguish one unit from another. For example, without departing from the scope of the exemplary embodiments, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0024] To achieve the above objectives, please refer to Figures 1 to 3 A method for managing a MES system based on lightweight intelligent manufacturing of glass containers is disclosed. The lightweight intelligent manufacturing process for glass containers includes a row-type machine with a multi-cavity cooling air system. The cooling air system includes a main pipe and cooling air branch pipes connected to each cavity. Each cooling air branch pipe is equipped with a switch-type solenoid valve, and the main pipe is equipped with a pressure sensor. A cold end wall thickness detection device is also installed at the rear end of the row-type machine. The method includes the following steps:

[0025] See Figure 2 This diagram illustrates the connection relationship of the cold-end wall thickness detection device in lightweight intelligent manufacturing of glass containers. It shows the hardware connection structure between the cooling air system of the conveyor and the detection equipment. A pressure sensor is installed on the main cooling air duct, and multiple cooling air branch ducts branch from the main duct. Each branch duct is equipped with a switch-type solenoid valve corresponding to a specific mold cavity. Solid lines represent the cooling airflow direction, dashed lines represent detection signals, and dotted lines represent control signals issued by the MES (Manufacturing Execution System). The cold-end wall thickness detection device is located on the rear conveyor line of the conveyor. The wall thickness detection signal and the main duct pressure sensor signal are sent to the MES system. The MES outputs control signals to control the solenoid valves of each branch duct to asynchronously open and close.

[0026] Preferably, step S1: the cold end wall thickness detection device obtains the wall thickness deviation information of each mold cavity according to the mold cavity number; and the pressure fluctuation signal collected by the main pipe pressure sensor is obtained.

[0027] Optionally, the specific steps in step S1 for obtaining the pressure fluctuation signal collected by the main pipe pressure sensor are as follows:

[0028] Using the molding cycle start signal output by the row machine controller as the time reference, the pressure signal output by the main pipe pressure sensor is divided into cycles.

[0029] Perform first-order differential operation on the pressure signal in each forming cycle after segmentation, mark the zero-crossing point where the differential value changes from positive to negative as the peak phase, and mark the zero-crossing point where the differential value changes from negative to positive as the trough phase;

[0030] The peak phase and trough phase are arranged in the order of the forming cycle to form a pressure phase reference. At the same time, the peak pressure value sequence corresponding to each peak phase and the trough pressure value sequence corresponding to each trough phase are recorded.

[0031] In one embodiment, the MES system establishes data communication with the machine controller via industrial Ethernet, receiving the molding cycle start pulse signal output by the machine controller at the beginning of each molding cycle. The rising edge of this pulse signal serves as the time reference for pressure signal acquisition. A main pipe pressure sensor, installed on the cooling air main duct, has a range of 0 to 100 kPa and outputs a 4 to 20 mA analog current signal, which is converted into a digital pressure value by an analog input module. The resolution of the converted digital pressure value is 0.01 kPa. The analog input module samples the output signal of the main pipe pressure sensor at a fixed sampling period; exemplarily, the sampling period is 10 ms, i.e., the sampling frequency is 100 Hz. The MES system uses the rising edge of the molding cycle start pulse signal as the trigger point to acquire main pipe pressure signal data for a complete molding cycle. For example, if the forming cycle of the forming machine is 3 seconds, then 300 pressure sampling points are collected in time sequence for each forming cycle, which are recorded as P[0], P[1], P[2]...P

[299] , where P[0] corresponds to the pressure value at the beginning of the forming cycle and P

[299] corresponds to the pressure value of the last sampling point before the end of the forming cycle.

[0032] Specifically, the MES system performs a first-order difference operation on the pressure sampling point sequence collected in each molding cycle. The specific operation is as follows: starting from the second sampling point, the pressure difference between the current sampling point and the previous sampling point is calculated sequentially to obtain the difference sequence D[i] = P[i] - P[i-1], where i = 1, 2, ..., 299. For each adjacent difference value in the difference sequence, a sign judgment is performed: if the value of D[i-1] is positive and the value of D[i] is negative, then the position corresponding to the i-th sampling point is determined to be a peak phase; if the value of D[i-1] is negative and the value of D[i] is positive, then the position corresponding to the i-th sampling point is determined to be a trough phase. For example, when i=100, P

[99] =75.2kPa, P

[100] =75.8kPa, then D

[100] =0.6kPa; when i=101, P

[101] =75.6kPa, then D

[101] =-0.2kPa; since D

[100] is positive and D

[101] is negative, the sampling point index 101 is marked as the peak phase, and the peak pressure value corresponding to this peak phase is P

[101] =75.6kPa. Similarly, if the subsequent difference value changes from negative to positive, the corresponding position is marked as the trough phase, and the trough pressure value corresponding to this trough phase is recorded. The MES system represents the marked peak phase by the sampling point index or the sampling time. For example, the sampling time corresponding to the sampling point index 101 is 101×10ms=1.01 seconds.

[0033] In another embodiment, the MES system arranges the peak and trough phases identified in each molding cycle according to the time sequence of the molding cycle to form a pressure phase reference. The pressure phase reference includes the following four sequences: peak phase sequence, peak pressure value sequence, trough phase sequence, and trough pressure value sequence. Taking three consecutive molding cycles as an example: In the first molding cycle, the peak phase index is identified as 101, the peak pressure value is 75.6 kPa, the trough phase index is 210, and the trough pressure value is 62.3 kPa; In the second molding cycle, the peak phase index is identified as 99, the peak pressure value is 76.1 kPa, the trough phase index is 208, and the trough pressure value is 61.8 kPa; In the third molding cycle, the peak phase index is identified as 102, the peak pressure value is 75.3 kPa, the trough phase index is 211, and the trough pressure value is 62.5 kPa. The MES system stores the peak phase index and peak pressure value into the peak phase sequence and peak pressure value sequence, respectively, and stores the trough phase index and trough pressure value into the trough phase sequence and trough pressure value sequence, respectively. These four sequences are then stored in the MES system's real-time database as pressure phase references.

[0034] Preferably, step S2: Based on the wall thickness deviation information and pressure fluctuation signal, determine the opening phase offset of the cooling air solenoid valve of each mold cavity during the molding cycle; wherein, the opening phase offset of the mold cavity with lower wall thickness exceeds the limit so that the total pipe pressure value corresponding to the opening time of the solenoid valve of that mold cavity is greater than the total pipe pressure value corresponding to the opening phase offset of the mold cavity with higher wall thickness exceeds the limit, and the magnitude of the phase offset corresponds to the amplitude of the wall thickness deviation.

[0035] Optionally, in step S2, determining the opening phase offset of the cooling air solenoid valve of each mold cavity during the molding cycle based on the wall thickness deviation information and pressure fluctuation signal includes:

[0036] Retrieve the upper and lower boundary values ​​of the standard wall thickness band from the preset lightweight glass container process parameter library;

[0037] The wall thickness deviation of each cavity is compared with the upper boundary value and the lower boundary value of the standard wall thickness band, respectively. Cavities with a wall thickness deviation value less than the lower boundary value of the standard wall thickness band are classified as cavities with lower wall thickness exceeding the limit; cavities with a wall thickness deviation value greater than the upper boundary value of the standard wall thickness band are classified as cavities with upper wall thickness exceeding the limit; and the remaining cavities are classified as cavities with normal wall thickness.

[0038] Obtain the peak and trough phases within the current forming cycle from the pressure phase reference;

[0039] The opening phase of the over-limit cavity with lower wall thickness is shifted towards the peak phase, and the opening phase of the over-limit cavity with higher wall thickness is shifted towards the trough phase.

[0040] In one embodiment, the MES system retrieves the upper and lower boundary values ​​of the standard wall thickness band from a preset lightweight glass container process parameter library. This process parameter library is stored in the MES system's historical database and organized by product model. For example, the target wall thickness of the current lightweight glass container product is 2.00 mm, the upper boundary value of the standard wall thickness band is set to 2.05 mm, and the lower boundary value is set to 1.95 mm. The MES system obtains the wall thickness deviation values ​​of each mold cavity from the cold-end wall thickness detection device, analyzed according to the mold cavity number. For example, the row-and-column machine has 6 mold cavities, numbered 1 to 6, and the corresponding wall thickness deviation values ​​are recorded as ΔW1=-0.08 mm, ΔW2=+0.06 mm, ΔW3=-0.01 mm, ΔW4=+0.03 mm, ΔW5=-0.12 mm, and ΔW6=+0.07 mm.

[0041] It should be noted that the MES system compares the wall thickness deviation values ​​of each cavity with the upper and lower boundary values ​​of the standard wall thickness band, respectively. For cavity 1, ΔW1 = -0.08mm, which is less than the lower deviation limit of -0.05mm corresponding to the lower boundary value of 1.95mm of the standard wall thickness band. Therefore, cavity 1 is classified as a cavity with a lower wall thickness exceeding the limit. For cavity 2, ΔW2 = +0.06mm, which is greater than the upper deviation limit of 2.05mm corresponding to the upper boundary value of 2.05mm of the standard wall thickness band. Therefore, cavity 2 is classified as a cavity exceeding the upper wall thickness limit; for cavity 3, ΔW3=-0.01mm, which is between -0.05mm and +0.05mm, it is classified as a cavity with normal wall thickness; for cavity 4, ΔW4=+0.03mm, it is also classified as a cavity with normal wall thickness; for cavity 5, ΔW5=-0.12mm, it is classified as a cavity exceeding the lower wall thickness limit; for cavity 6, ΔW6=+0.07mm, it is classified as a cavity exceeding the upper wall thickness limit. The MES system records the classification results sequentially according to the cavity number, forming a cavity classification table, where cavity 1 and cavity 5 are cavities exceeding the lower wall thickness limit, cavity 2 and cavity 6 are cavities exceeding the upper wall thickness limit, and cavity 3 and cavity 4 are cavities with normal wall thickness.

[0042] In another embodiment, the MES system obtains the peak and trough phases within the current molding cycle from the pressure phase reference. The pressure phase reference is stored in the MES system's real-time database. The peak phase sampling point index for the current molding cycle is 101, corresponding to a sampling time of 1010ms, with a peak pressure value of 75.6kPa. The trough phase sampling point index is 210, corresponding to a sampling time of 2100ms, with a trough pressure value of 62.3kPa. The MES system also obtains the reference opening phase of the cooling air solenoid valves for each mold cavity. The reference opening phase is determined by dividing the molding cycle into six time slots, each with a length of 500ms. The reference opening phases for mold cavities 1 to 6 are 0ms, 500ms, 1000ms, 1500ms, 2000ms, and 2500ms, respectively.

[0043] Furthermore, the MES system determines the offset direction of the opening phase of each cavity based on the cavity classification results and the pressure phase reference: for cavities exceeding the wall thickness limit, namely cavities 1 and 5, the opening phase is offset from their respective reference opening phase towards the peak phase of 1010ms; for cavities exceeding the wall thickness limit, namely cavities 2 and 6, the opening phase is offset from their respective reference opening phase towards the trough phase of 2100ms; for cavities with normal wall thickness, namely cavities 3 and 4, the opening phase remains unchanged at the reference opening phase.

[0044] Optionally, the magnitude of the phase offset in step S2, corresponding to the amplitude of the wall thickness deviation, includes:

[0045] Obtain the actual length and diameter of the cooling air branch pipes for each mold cavity of the row machine;

[0046] The characteristic value of the cooling air branch pipe resistance of each mold cavity is determined based on the actual length and diameter;

[0047] The average value of the resistance characteristic value of the cooling air branch pipes of all mold cavities is obtained as the standard resistance characteristic value;

[0048] For the wall thickness exceeding the limit mold cavity, the phase offset is set to the phase difference between the current opening phase and the peak phase multiplied by the ratio of the characteristic value of the cooling air branch pipe resistance of the mold cavity to the characteristic value of the standard resistance.

[0049] For mold cavities with excessive wall thickness, the phase offset is set to the phase difference between the current opening phase and the trough phase multiplied by the ratio of the characteristic value of the cooling air branch pipe resistance of the mold cavity to the characteristic value of the standard resistance.

[0050] In one embodiment, the MES system obtains the actual length and diameter of the cooling air branch pipes for each mold cavity from the machine tool parameter database. Each mold cavity cooling air branch pipe of the machine tool cooling air system is connected to the main pipe, and the length and diameter of each branch pipe vary depending on the installation position of the mold cavity on the machine tool. For example, the machine tool has six mold cavities. The actual lengths of the cooling air branch pipes for mold cavities 1 to 6 are denoted as L1=1200mm, L2=1000mm, L3=1100mm, L4=1050mm, L5=1250mm, and L6=980mm, respectively; the diameters of each cooling air branch pipe are denoted as D1=25mm, D2=25mm, D3=28mm, D4=28mm, D5=22mm, and D6=25mm, respectively. The MES system calculates the characteristic resistance value of the cooling air branch pipes for each mold cavity based on their actual length and diameter. The calculation formula is: the characteristic resistance value of the cooling air branch pipe is equal to the actual length of the branch pipe divided by the fourth power of the branch pipe diameter, i.e. .

[0051] For example, the characteristic value of the resistance of the cooling air branch pipe of mold cavity 1:

[0052] R1=1200 / 25 4 =1200 / 390625=0.003072; Characteristic value of the resistance of the cooling air branch pipe of mold cavity 2;

[0053] R² = 1000 / 25 4 =1000 / 390625=0.002560; Characteristic value of the resistance of the cooling air branch pipe of mold cavity 3;

[0054] R3=1100 / 28 4 =1100 / 614656=0.001789; Characteristic value of the resistance of the cooling air branch pipe of mold cavity 4;

[0055] R4=1050 / 284 =1050 / 614656=0.001708; Characteristic value of the resistance of the cooling air branch pipe of mold cavity 5;

[0056] R5=1250 / 22 4 =1250 / 234256=0.005336; Characteristic value of the resistance of the cooling air branch pipe of mold cavity 6;

[0057] R6=980 / 25 4 =980 / 390625=0.002509.

[0058] In another embodiment, the MES system obtains the average value of the resistance characteristic values ​​of all mold cavity cooling air branch pipes as the standard resistance characteristic value, denoted as R_std. The calculation process is as follows: the resistance characteristic values ​​of the cooling air branch pipes of mold cavities 1 to 6 are added sequentially to obtain the sum R_sum = 0.003072 + 0.002560 + 0.001789 + 0.001708 + 0.005336 + 0.002509 = 0.016974; then the sum is divided by the total number of mold cavities, 6, to obtain the standard resistance characteristic value R_std = 0.016974 / 6 = 0.002829. The MES system stores the calculated resistance characteristic values ​​R1 to R6 of each mold cavity cooling air branch pipe and the standard resistance characteristic value R_std in a real-time database.

[0059] Further, based on the cavity classification results output from the previous processing step, the MES system calculates the phase offset for each cavity exceeding the lower and upper wall thickness limits. Cavities 1 and 5 are cavities exceeding the lower wall thickness limits, while cavities 2 and 6 are cavities exceeding the upper wall thickness limits. The current activation phases are: 0ms for cavity 1, 2000ms for cavity 5, 500ms for cavity 2, and 2500ms for cavity 6. The peak phase within the current molding cycle is 1010ms, and the trough phase is 2100ms. For cavities exceeding the lower wall thickness limits, the phase offset is equal to the phase difference between the current activation phase and the peak phase multiplied by the ratio of the characteristic value of the cooling air branch pipe resistance of that cavity to the standard resistance characteristic value. The phase difference of cavity 1 is 1010-0=1010ms, the ratio R1 / R_std=0.003072 / 0.002829=1.086, and the phase offset is 1010×1.086=1096.9ms; the phase difference of cavity 5 is 2000-1010=990ms, the ratio R5 / R_std=0.005336 / 0.002829=1.886, and the phase offset is 990×1.886=1867.1ms.

[0060] The MES system continues to calculate the phase offset of the cavity exceeding the wall thickness limit. For the cavity exceeding the wall thickness limit, the phase offset is equal to the phase difference between the current opening phase and the trough phase multiplied by the ratio of the characteristic value of the cooling air branch resistance of the cavity to the characteristic value of the standard resistance. The phase difference of cavity 2 is 2100-500=1600ms, the ratio R2 / R_std=0.002560 / 0.002829=0.905, and the phase offset is 1600×0.905=1448.0ms; the phase difference of cavity 6 is 2500-2100=400ms, the ratio R6 / R_std=0.002509 / 0.002829=0.887, and the phase offset is 400×0.887=354.8ms. Cavities 3 and 4 are cavities with normal wall thickness, and their phase offsets remain at 0.

[0061] Optionally, after obtaining the phase offset of each mold cavity, compensation for the pressure propagation delay in the cooling air branch pipe is also included, specifically:

[0062] Obtain the length information of the cooling air branch pipes for each mold cavity of the row machine;

[0063] Based on the propagation speed of the cooling air in the branch pipe and the length of the branch pipe, calculate the phase delay of the pressure wave of each mold cavity from the main pipe to the solenoid valve of that mold cavity.

[0064] Add the phase offset to the phase delay to obtain the phase offset after delay compensation;

[0065] Arrange the opening phases of each mold cavity after delay compensation in chronological order. If the opening phase interval between adjacent mold cavities is less than the preset minimum opening phase interval, then shift the opening phase of the next mold cavity backward to the position that satisfies the minimum opening phase interval.

[0066] If, after translation, the total pipe pressure value corresponding to the opening moment of the mold cavity does not meet the requirement that the total pipe pressure value corresponding to the opening moment of the lower wall thickness limit mold cavity is greater than the total pipe pressure value corresponding to the opening moment of the upper wall thickness limit mold cavity, then the opening phase of the mold cavity will be repositioned to the next phase position that meets the pressure requirement.

[0067] In one embodiment, the MES system obtains the actual length of the cooling air branch pipes for each mold cavity from the machine tool parameter database. For example, the lengths of the cooling air branch pipes for mold cavities 1 to 6 are L1=1200mm, L2=1000mm, L3=1100mm, L4=1050mm, L5=1250mm, and L6=980mm, respectively. The MES system retrieves the cooling air propagation velocity v_air=340m / s from the process parameter database and calculates it according to the formula... Calculate the phase delay of the pressure wave from the main pipe to the solenoid valve of each cavity: 3.53ms for cavity 1, 2.94ms for cavity 2, 3.24ms for cavity 3, 3.09ms for cavity 4, 3.68ms for cavity 5, and 2.88ms for cavity 6.

[0068] Specifically, the MES system reads the phase offset of each cavity from the cavity phase offset table, adds it to the corresponding phase delay, and obtains the phase offset after delay compensation. Taking cavity 1 as an example, its phase offset is 1096.9ms, and its phase delay is 3.53ms, which adds up to 1100.43ms; the phase offset of cavity 5 is 1867.1ms, which is 1870.78ms after delay compensation; the phase offset of cavity 2 is 1448.0ms, which is 1450.94ms after delay compensation; the phase offset of cavity 6 is 354.8ms, which is 357.68ms after delay compensation; the phase offsets of cavities 3 and 4 are both 0, and after delay compensation, they are 3.24ms and 3.09ms respectively. The actual opening phases are obtained by adding the reference opening phase of each cavity to the phase offset after delay compensation: 1100.43ms for cavity 1, 1950.94ms for cavity 2, 1003.24ms for cavity 3, 1503.09ms for cavity 4, 3870.78ms for cavity 5, and 2857.68ms for cavity 6. The actual opening phase of cavity 5 exceeds the molding cycle time by 3000ms; subtracting the molding cycle time yields an equivalent actual opening phase of 870.78ms.

[0069] In another embodiment, the MES system arranges the actual opening phases or equivalent actual opening phases of each mold cavity in chronological order, as follows: equivalent actual opening phase of mold cavity 5 is 870.78ms, actual opening phase of mold cavity 3 is 1003.24ms, actual opening phase of mold cavity 1 is 1100.43ms, actual opening phase of mold cavity 4 is 1503.09ms, actual opening phase of mold cavity 2 is 1950.94ms, and actual opening phase of mold cavity 6 is 2857.68ms. The MES system retrieves the preset minimum opening phase interval of 80ms and checks the adjacent actual opening phase intervals in sequence: 132.46ms, 97.19ms, 402.66ms, 447.85ms, and 906.74ms. Since all of them are greater than 80ms, no shift or translation is performed.

[0070] It should be noted that the MES system reads the total pipe pressure value corresponding to each actual opening phase based on the current molding cycle pressure sampling sequence: cavity 5 is 74.2 kPa, cavity 3 is 75.5 kPa, cavity 1 is 75.1 kPa, cavity 4 is 70.3 kPa, cavity 2 is 64.8 kPa, and cavity 6 is 68.5 kPa. Among them, the lower wall thickness exceeding the limit mold cavities are cavity 5 and cavity 1, and the upper wall thickness exceeding the limit mold cavities are cavity 2 and cavity 6. The MES system checks whether the total pipe pressure value at the opening time of the lower wall thickness exceeding the limit mold cavities is greater than the total pipe pressure value at the opening time of the upper wall thickness exceeding the limit mold cavities: 74.2 kPa is greater than 64.8 kPa and 68.5 kPa, and 75.1 kPa is greater than 64.8 kPa and 68.5 kPa. All requirements are met, and repositioning is not performed.

[0071] Most importantly, after completing the delay compensation and opening phase interval adjustment, it also includes binding the cavity opening phase with the mold opening and closing stage, specifically:

[0072] Obtain the initial mold closing position signal and the initial mold opening position signal from the column machine controller;

[0073] The time period between the initial mold closing signal and the initial mold opening signal is defined as the mold closing stage, and the time period between the initial mold opening signal and the initial mold closing signal of the next molding cycle is defined as the mold opening stage.

[0074] Check the opening phase of each mold cavity. If the opening phase of a mold cavity with a wall thickness exceeding the limit falls into the mold opening phase, then adjust the opening phase to the nearest phase position within the mold closing phase that meets the main pipe pressure value requirement.

[0075] If the opening phase of the mold cavity exceeds the wall thickness limit and falls into the mold closing stage, then the opening phase should be adjusted to the nearest phase position within the mold opening stage that meets the main pipe pressure requirement.

[0076] In one embodiment, the MES system obtains the initial mold closing and opening signals from the molding machine controller, recording the initial mold closing signal time as 1000ms and the initial mold opening signal time as 2500ms within the molding cycle. The MES system defines the time period between the initial mold closing and opening signals as the mold closing stage, i.e., [1000ms, 2500ms]; and defines the time period between the initial mold opening signal and the initial mold closing signal of the next molding cycle as the mold opening stage, which is divided into two intervals within the current molding cycle: [2500ms, 3000ms] and [0ms, 1000ms]. The MES system writes the stage division results into a real-time database as the basis for determining the stage of mold cavity opening phase binding.

[0077] Furthermore, the MES system reads the actual opening phase of each cavity after delay compensation and opening phase interval adjustment from the cavity asynchronous switch control module. The equivalent actual opening phase of cavity 5 is 870.78ms, the actual opening phase of cavity 3 is 1003.24ms, the actual opening phase of cavity 1 is 1100.43ms, the actual opening phase of cavity 4 is 1503.09ms, the actual opening phase of cavity 2 is 1950.94ms, and the actual opening phase of cavity 6 is 2857.68ms. The MES system sequentially checks the opening phase of each mold cavity: Cavity 5's opening phase is 870.78ms, falling into the mold opening stage; Cavity 3's opening phase is 1003.24ms, falling into the mold closing stage; Cavity 1's opening phase is 1100.43ms, falling into the mold closing stage; Cavity 4's opening phase is 1503.09ms, falling into the mold closing stage; Cavity 2's opening phase is 1950.94ms, falling into the mold closing stage; and Cavity 6's opening phase is 2857.68ms, falling into the mold opening stage. Cavity 5 is a lower wall thickness limit-exceeding cavity, and its opening phase falls into the mold opening stage. It needs to be adjusted to the nearest phase position within the mold closing stage that meets the main pipe pressure requirement. Cavity 2 is an upper wall thickness limit-exceeding cavity, and its opening phase falls into the mold closing stage. It also needs to be adjusted to the nearest phase position within the mold opening stage that meets the main pipe pressure requirement. The opening phases of the remaining cavities match the cavity type and do not require adjustment.

[0078] It should be noted that the MES system adjusts cavity 5, changing its opening phase from 870.78ms to 1000ms, the boundary position of the mold closing stage. The total pipe pressure value at 1000ms, read from the current molding cycle pressure sampling sequence, is 75.5 kPa. The MES system also adjusts cavity 2, changing its opening phase from 1950.94ms to 2500ms, the nearest boundary position of the mold opening stage. The total pipe pressure value at 2500ms, read from the pressure sampling sequence, is 60.2 kPa. The MES system checks whether the total pipe pressure value corresponding to the opening moment of the cavity exceeding the wall thickness limit is greater than the total pipe pressure value corresponding to the opening moment of the cavity exceeding the wall thickness limit. The adjusted pressure value of cavity 5 (75.5 kPa) is greater than the adjusted pressure value of cavity 2 (60.2 kPa), thus meeting the requirements. The MES system updates the opening phases of each mold cavity to: 1000ms for mold cavity 5, 1003.24ms for mold cavity 3, 1100.43ms for mold cavity 1, 1503.09ms for mold cavity 4, 2500ms for mold cavity 2, and 2857.68ms for mold cavity 6. The updated opening phases are then output as the final opening phases to the asynchronous switching control steps of the mold cavity solenoid valves.

[0079] Of particular importance is that after determining the phase offset of each cavity, a feedforward correction based on the historical wall thickness deviation trend is also included, specifically:

[0080] Extract wall thickness deviation records of consecutive batches of the same mold cavity from the historical database of the MES system, and simultaneously extract the position records of the opening phase of the mold cavity in the corresponding mold stage and the resistance characteristic value of the cooling air branch pipe of the mold cavity within the corresponding batch.

[0081] The number of batches in which the wall thickness deviation and the opening phase position offset change continuously in the same direction and the magnitude of change increases;

[0082] When the number of batches reaches the number of batches confirmed by the trend, the difference in wall thickness deviation between the last batch and the previous batch in the change sequence is multiplied by the resistance characteristic value of the cooling air branch pipe of the mold cavity to obtain the deviation correction component; the difference in opening phase position offset between the last batch and the previous batch is multiplied by the pressure propagation delay of the cooling air branch pipe of the mold cavity to obtain the phase correction component.

[0083] The deviation correction component and the phase correction component are superimposed to obtain the feedforward correction amount, which is then superimposed on the current phase offset to obtain the final phase offset amount.

[0084] If the batch quantity does not reach the number of batches confirmed by the trend, the current phase offset remains unchanged.

[0085] In one embodiment, the MES system extracts wall thickness deviation records for consecutive batches of the same mold cavity from a historical database. Simultaneously, it extracts the position record of the mold cavity opening phase within the corresponding batch during the mold stage, as well as the resistance characteristic value of the mold cavity's cooling air branch pipe. For example, taking mold cavity 1 as the object, records for the most recent five consecutive batches are extracted. The resistance characteristic value R1 of the cooling air branch pipe for mold cavity 1 is 0.003072, the pressure propagation delay Δt1 of the cooling air branch pipe for mold cavity 1 is 3.53 ms, and the molding cycle length is 3000 ms. The wall thickness deviation values ​​of the most recent five batches of mold cavity 1, in chronological order, are -0.06 mm, -0.07 mm, -0.08 mm, -0.09 mm, and -0.10 mm; the position offset of the mold cavity 1 opening phase during the mold closing stage is 80 ms, 85 ms, 90 ms, 96 ms, and 103 ms, respectively.

[0086] Specifically, the MES system performs trend judgment on the wall thickness deviation and the opening phase position offset. The wall thickness deviation continuously changes in the negative direction from -0.06mm to -0.10mm, with the differences between adjacent batches being -0.01mm, -0.01mm, -0.01mm, and -0.01mm respectively, showing a consistent direction of change and a stable amplitude. The opening phase position offset continuously increases from 80ms to 103ms, with the differences between adjacent batches being 5ms, 5ms, 6ms, and 7ms respectively, showing a consistent direction of change and an increasing amplitude. The MES system counts the number of batches that simultaneously satisfy both the continuous wall thickness deviation and the continuous opening phase position offset changing in the same direction with increasing amplitude. In this embodiment, the number of such batches is 5, which is greater than the preset trend confirmation batch number of 3, thus determining that mold cavity 1 meets the feedforward correction execution conditions.

[0087] In another embodiment, the MES system takes the difference in wall thickness deviation between the last batch and the previous batch in the variation sequence. The wall thickness deviation of the last batch is -0.10mm, and the wall thickness deviation of the previous batch is -0.09mm, with a difference of -0.01mm. This difference is multiplied by the characteristic value of the cooling air branch pipe resistance of mold cavity 1 (0.003072), and then multiplied by the preset wall thickness deviation-phase conversion coefficient (1000ms / mm) to calculate the deviation correction component as -0.01×0.003072×1000=-0.03072ms. The MES system takes the difference in the opening phase position offset between the last batch and the previous batch. The offset of the last batch is 103ms, and the offset of the previous batch is 96ms, with a difference of 7ms. This 7ms is multiplied by the pressure propagation delay of the cooling air branch pipe of mold cavity 1 (3.53ms), and then divided by the molding cycle length (3000ms) to calculate the phase correction component as 7×3.53 / 3000=0.00824ms. The MES system superimposes the deviation correction component -0.03072ms and the phase correction component 0.00824ms to obtain a feedforward correction amount of -0.02248ms, and then adds this feedforward correction amount to the current phase offset of cavity 1. For example, if the current phase offset of cavity 1 is 1096.9ms, the final phase offset after superposition is 1096.88ms.

[0088] For cavities that do not meet the batch number condition for trend confirmation, the MES system does not perform the aforementioned feedforward correction operation and maintains their current phase offset unchanged. The MES system updates the final phase offset of each cavity to the cavity phase offset table, which serves as the input data for subsequent asynchronous switching control of the cavity solenoid valves.

[0089] Preferably, in step S3: control the cooling air solenoid valves of each mold cavity to perform asynchronous switching actions according to a determined phase offset, the opening phases of each mold cavity are staggered during the molding cycle, and the total pipe pressure value at the opening time of each mold cavity solenoid valve is determined by the opening phase.

[0090] Optionally, step S3, controlling the asynchronous switching action of the cooling air solenoid valves of each mold cavity according to a determined phase offset, includes:

[0091] Obtain the total number of mold cavities in the row and column machine, divide the molding cycle evenly into time slots of equal length equal to the total number of mold cavities, and assign each mold cavity to the corresponding time slot according to the mold cavity number sequence;

[0092] The opening time of each mold cavity solenoid valve is set to the start time of its corresponding time slot, and the closing time is set to the end time of that time slot;

[0093] When a certain mold cavity has a phase offset, the opening time is offset by the phase offset within the corresponding time slot of the mold cavity and then used as the actual opening time. After the offset, the opening time is still within the time slot.

[0094] In this embodiment, the MES system obtains the total number of mold cavities N_mold from the row and column machine controller, exemplarily, N_mold=6; and retrieves the molding cycle length T_cycle from the process parameter library, exemplarily, T_cycle=3000ms. The molding cycle is evenly divided into 6 equal-length time slots, each time slot length T_slot=T_cycle / N_mold=3000 / 6=500ms. The time slots are allocated according to the mold cavity number order: mold cavity 1 corresponds to [0, 500ms], mold cavity 2 corresponds to [500ms, 1000ms], mold cavity 3 corresponds to [1000ms, 1500ms], mold cavity 4 corresponds to [1500ms, 2000ms], mold cavity 5 corresponds to [2000ms, 2500ms], and mold cavity 6 corresponds to [2500ms, 3000ms]. The reference opening times of the solenoid valves in each mold cavity are set sequentially to 0ms, 500ms, 1000ms, 1500ms, 2000ms, and 2500ms, and the reference closing times are set sequentially to 500ms, 1000ms, 1500ms, 2000ms, 2500ms, and 3000ms.

[0095] Specifically, the MES system reads the final phase offset of each cavity after feedforward correction from the cavity phase offset table. For example, cavity 1 is +100ms, cavity 2 is -50ms, cavity 3 is 0ms, cavity 4 is +80ms, cavity 5 is -120ms, and cavity 6 is +40ms. The absolute value of each offset is less than the time slot length of 500ms. The reference start time of each cavity is added to its corresponding phase offset to obtain the actual start time: cavity 1 is 100ms, cavity 2 is 450ms, cavity 3 is 1000ms, cavity 4 is 1580ms, cavity 5 is 1880ms, and cavity 6 is 2540ms. Each actual start time falls within its corresponding time slot.

[0096] Furthermore, the MES system combines the actual start-up time with the reference stop-down time to form switch control commands: Cavity 1 opens at 100ms and closes at 500ms; Cavity 2 opens at 450ms and closes at 1000ms; Cavity 3 opens at 1000ms and closes at 1500ms; Cavity 4 opens at 1580ms and closes at 2000ms; Cavity 5 opens at 1880ms and closes at 2500ms; Cavity 6 opens at 2540ms and closes at 3000ms. The MES system writes these commands into the cavity solenoid valve control queue in chronological order and sends them to the corresponding cavity solenoid valve drive module via industrial Ethernet at the start of each molding cycle to execute asynchronous switching actions.

[0097] Optionally, the asynchronous switching of the cooling air solenoid valves for each mold cavity also includes dynamic correction of the opening timing based on real-time pressure feedback, specifically:

[0098] Extract the expected main pipe pressure value corresponding to the opening phase of each mold cavity from the pressure fluctuation signal;

[0099] When the original scheduled opening time of a certain mold cavity is reached, read the real-time pressure value of the main pipe pressure sensor.

[0100] If the real-time pressure value is lower than the expected main pipe pressure value, the solenoid valve of the mold cavity will not be opened temporarily. The real-time pressure value will be continuously read until the real-time pressure value rises back to the expected main pipe pressure value, and then it will be opened immediately.

[0101] If the real-time pressure value is higher than the expected main pipe pressure value, the solenoid valve of the mold cavity will be opened immediately.

[0102] In this embodiment, the MES system extracts the expected main pipe pressure value corresponding to the opening phase of each mold cavity from the pressure phase reference and the current molding cycle pressure sampling sequence. The main pipe pressure sampling period is exemplarily 10ms. The sampling point index is obtained by dividing the actual opening time of each mold cavity by the sampling period, and the corresponding pressure value is read from the pressure sampling sequence. For example, the actual opening time of mold cavity 1 is 100ms, the sampling point index is 10, and the expected main pipe pressure value P_expect_1 = 72.5kPa; the actual opening time of mold cavity 2 is 450ms, the sampling point index is 45, and the expected main pipe pressure value P_expect_2 = 68.0kPa; the expected main pipe pressure values ​​of mold cavities 4, 5, and 6 are read in the same way as 70.3kPa, 65.2kPa, and 67.8kPa, respectively.

[0103] When the scheduled opening time of cavity 1 is reached 100ms, the MES system reads a real-time pressure value of 70.8 kPa from the main pipe pressure sensor, which is lower than the expected main pipe pressure value of 72.5 kPa. Therefore, it does not send an opening command to the solenoid valve drive module of cavity 1. Instead, it continuously reads the real-time pressure value at a sampling period of 10ms, successively obtaining readings of 71.2 kPa, 71.6 kPa, 72.0 kPa, and 72.4 kPa. When the real-time pressure value rises back to 72.5 kPa, the solenoid valve of cavity 1 is immediately opened. When the scheduled opening time of cavity 2 is reached 450ms, the real-time pressure value is read as 69.5 kPa, which is higher than the expected main pipe pressure value of 68.0 kPa. Therefore, the solenoid valve of cavity 2 is immediately opened. Cavities 4, 5, and 6 are handled in the same manner: if the real-time pressure value is lower than the expected main pipe pressure value, they are not opened temporarily and are continuously read until they rise back to the expected value before opening; if the real-time pressure value is higher than the expected main pipe pressure value, they are opened immediately. The MES system updates the actual opening time of each mold cavity after correction to the real-time database and records the real-time pressure value sequence during the correction process. If the real-time pressure value of a certain mold cavity has not risen to the expected total pipe pressure value by the end of the corresponding time slot, the solenoid valve of that mold cavity will remain closed in this cycle, and the dynamic correction of the opening time will be re-executed in the next molding cycle.

[0104] Optionally, the asynchronous switching of the cooling air solenoid valves for each mold cavity also includes adjusting the opening and closing times based on pressure peaks, specifically:

[0105] For the mold cavity with a wall thickness exceeding the limit, after the solenoid valve is opened, the real-time value of the main pipe pressure is continuously read. When the real-time pressure value rises from the pressure value corresponding to the opening time and reaches the peak and then falls back to the pressure value corresponding to the opening time, the solenoid valve is closed.

[0106] For mold cavities with wall thickness exceeding the limit, if the real-time pressure value exceeds the product of the peak pressure value in the current cycle and the preset proportional factor after the solenoid valve is opened, the solenoid valve will be closed in advance; wherein, the peak pressure value is dynamically updated and determined by the maximum pressure value in the sliding window.

[0107] In this embodiment, after the cavity solenoid valve is opened, the MES system establishes a sliding pressure monitoring window with the sampling period of the main pipe pressure sensor as the step size. For example, the sampling period is 10ms, and the sliding window length is set to 10 sampling points, i.e., the window time span is 100ms. The main pipe pressure values ​​of the 10 most recent sampling points are stored in real time within the window, and the maximum pressure value within the window is used as the peak pressure value in the current period, denoted as P_peak_current. When a new sampling point arrives, the window slides one position backward, discarding the oldest sampling point, incorporating the latest sampling point, and recalculating the maximum value within the window to achieve dynamic updating of the peak pressure value. The MES system reads each cavity type from the cavity classification table; cavity 1 and cavity 5 are cavities exceeding the lower wall thickness limit, while cavity 2 and cavity 6 are cavities exceeding the upper wall thickness limit. The opening pressure value corresponding to the opening time of each cavity is denoted as P_open_i, which is determined by the dynamic correction step of the opening time and stored in the real-time correction table.

[0108] Specifically, taking cavity 1 as an example, cavity 1 is a cavity with a lower wall thickness limit. The opening time is 100ms, and the corresponding main pipe pressure value P_open_1 at the opening time is 72.5kPa. After the solenoid valve opens, the MES system continuously reads the real-time pressure value of the main pipe pressure sensor at a sampling period of 10ms. At the 5th sampling point after opening, i.e., at 150ms, the real-time pressure value is read as 76.0kPa, and the maximum pressure value within the window is updated to 76.0kPa; at the 8th sampling point, i.e., at 180ms, the real-time pressure value is read as 75.8kPa, which does not exceed the maximum value within the window; at the 10th sampling point, i.e., at 200ms, the real-time pressure value is read as 75.2kPa, which still does not exceed the limit; at the 12th sampling point, i.e., at 220ms, the real-time pressure value is read as 72.5kPa. The MES system determines that the real-time pressure value has risen to a peak and then fallen back to the opening pressure value of 72.5 kPa. It then sends a closing command to the solenoid valve drive module of cavity 1. The solenoid valve of cavity 1 closes in 220 ms, while the actual opening duration is 120 ms. Cavity 5 is also a cavity with a lower wall thickness limit; its opening time is 1880 ms, and its opening pressure value P_open_5 is 65.2 kPa. The MES system executes the same judgment logic, closing the solenoid valve of cavity 5 when the real-time pressure value rises from the opening pressure value, reaches a peak, and then falls back to 65.2 kPa.

[0109] Specifically, taking cavity 2 as an example, cavity 2 is a cavity with a wall thickness exceeding the limit. The opening time is 450ms, and the corresponding main pipe pressure value P_open_2 at the opening time is 68.0kPa. The MES system presets a scaling factor, which is set to 0.9 for example. After the solenoid valve opens, the peak pressure value in the sliding window is dynamically updated. At the third sampling point after opening, i.e., at 480ms, the real-time pressure value is read as 75.0kPa, and the peak pressure value P_peak_current in the window is updated to 75.0kPa. The MES system calculates that the product of the peak pressure value and the preset scaling factor is 75.0×0.9=67.5kPa. Comparing the real-time pressure value of 75.0kPa with this product, the real-time pressure value exceeds 67.5kPa. The MES system immediately sends a closing command to the solenoid valve drive module of cavity 2. The solenoid valve of cavity 2 closes ahead of schedule at 480ms, and the actual opening duration is 30ms. Cavity 6 is also a cavity exceeding the wall thickness limit. Its opening time is 2540ms, and the opening pressure value P_open_6 is 67.8kPa. The MES system executes the same judgment logic, and closes the solenoid valve of cavity 6 in advance when the real-time pressure value exceeds the product of the peak pressure value in the current window and the preset proportional factor. The MES system updates the adjusted closing time of each cavity to the real-time database and writes it into the cavity solenoid valve control queue along with the actual opening time.

[0110] Preferably, step S4: receive cold end wall thickness detection data, and update the phase offset of the cooling air solenoid valve of each mold cavity according to the cold end wall thickness detection data.

[0111] Optionally, updating the phase offset of the cooling air solenoid valve of each mold cavity based on the cold end wall thickness detection data in step S4 includes:

[0112] After the MES system receives the cold end wall thickness detection data of a new batch, it calculates the wall thickness deviation change rate of each mold cavity. The wall thickness deviation change rate is the difference between the wall thickness deviation of this batch and the wall thickness deviation of the previous batch divided by the time interval between the two batches.

[0113] When the direction of the wall thickness deviation change rate is consistent with the current phase offset adjustment direction, the phase offset update value is calculated based on the product of the absolute value of the change rate and the preset phase adjustment gain, and the current phase offset update value is superimposed on the phase offset of the cavity.

[0114] When the direction of the wall thickness deviation change rate is opposite to the direction of the current phase offset adjustment, the phase offset of the mold cavity remains unchanged.

[0115] In this embodiment, the MES system receives the wall thickness deviation data of each mold cavity output by the cold end wall thickness detection device for a new batch and records the receiving timestamp. The MES system retrieves the wall thickness deviation value and corresponding timestamp of the same mold cavity from the historical database for the previous batch, and calculates the time interval between the two batches. For example, the time interval between the two batches is 1800s. The wall thickness deviation value is conventionally defined as follows: a positive value indicates that the wall thickness is greater than the target wall thickness, and a negative value indicates that the wall thickness is less than the target wall thickness. The phase offset is conventionally defined as follows: a positive value indicates an offset towards the peak, and a negative value indicates an offset towards the trough. The MES system calculates the rate of change of the wall thickness deviation of each mold cavity, which is calculated by dividing the difference between the current wall thickness deviation value and the previous batch wall thickness deviation value by the time interval between the two batches.

[0116] For example, the wall thickness deviation of the previous batch in mold cavity 1 was -0.08 mm, and the current wall thickness deviation was -0.10 mm, with a wall thickness deviation change rate of (-0.10 - (-0.08)) / 1800 = -0.0000111 mm / s; the wall thickness deviation of the previous batch in mold cavity 5 was -0.05 mm, and the current wall thickness deviation was -0.03 mm, with a wall thickness deviation change rate of (-0.03 - (-0.05)) / 1800 = +0.0000111 mm / s; the wall thickness deviation of the previous batch in mold cavity 2 was +0.10 mm, and the current wall thickness deviation was +0.08 mm, with a wall thickness deviation change rate of (+0.08 - (+0.10)) / 1800 = -0.0000111mm / s; The wall thickness deviation of the previous batch of mold cavity 6 was +0.06mm, and the wall thickness deviation of this batch was +0.07mm. The wall thickness deviation change rate was (+0.07-(+0.06)) / 1800 = +0.00000556mm / s.

[0117] Furthermore, the MES system reads the current phase offset of each cavity from the cavity phase offset table: cavity 1 is +100ms, cavity 5 is +80ms, cavity 2 is -50ms, and cavity 6 is -120ms. The MES system retrieves a preset phase adjustment gain from the process parameter library; for example, the phase adjustment gain is 1,000,000ms / (mm / s). The MES system performs direction determination for each cavity: when the sign of the wall thickness deviation change rate is the same as the sign of the current phase offset, the direction is the same; when the signs are opposite, the direction is opposite.

[0118] The wall thickness deviation rate of cavity 1 is negative, while the current phase offset is positive, with opposite signs and directions. The current phase offset of cavity 1 is kept constant at +100ms. The wall thickness deviation rate of cavity 5 is positive, and the current phase offset is also positive, with the same sign and direction. The absolute value of the wall thickness deviation rate is multiplied by the phase adjustment gain to obtain the updated phase offset value: 0.0000111 × 1000000 = 11.1ms. This 11.1ms is then added to the current phase offset of cavity 5 +80ms, resulting in an updated phase offset of +91.1ms. The wall thickness deviation change rate of cavity 2 is negative, and the current phase offset is also negative, with the same sign and direction. Multiplying the absolute value of the wall thickness deviation change rate by the phase adjustment gain yields an updated phase offset value of 0.0000111 × 1000000 = 11.1 ms. The current phase offset is negative, so the updated phase offset is -50 + (-11.1) = -61.1 ms. The wall thickness deviation change rate of cavity 6 is positive, and the current phase offset is negative, with the opposite sign and direction. The current phase offset of cavity 6 remains unchanged at -120 ms. The MES system writes the updated phase offsets of each cavity into the cavity phase offset table for asynchronous switching control of the cavity solenoid valves in the next molding cycle.

[0119] This invention also provides a control system for a MES system based on lightweight intelligent manufacturing of glass containers, used to execute the above-described control method for the MES system based on lightweight intelligent manufacturing of glass containers. The control system for the MES system based on lightweight intelligent manufacturing of glass containers includes:

[0120] The mold cavity condition acquisition module is used to acquire the wall thickness deviation information of each mold cavity according to the mold cavity number by the cold end wall thickness detection device; and to acquire the pressure fluctuation signal collected by the main pipe pressure sensor.

[0121] The phase offset determination module is used to determine the opening phase offset of the cooling air solenoid valve of each mold cavity during the molding cycle based on the wall thickness deviation information and pressure fluctuation signal. Among them, the opening phase offset of the mold cavity with lower wall thickness limit makes the total pipe pressure value corresponding to the opening time of the solenoid valve of that mold cavity greater than the total pipe pressure value corresponding to the opening phase offset of the mold cavity with higher wall thickness limit, and the magnitude of the phase offset corresponds to the amplitude of the wall thickness deviation.

[0122] The asynchronous switch execution module is used to control the cooling air solenoid valves of each mold cavity to perform asynchronous switching actions according to a determined phase offset. The opening phases of each mold cavity are staggered during the molding cycle, and the total pipe pressure value at the opening time of each mold cavity solenoid valve is determined by the opening phase.

[0123] The phase offset update module is used by the MES system to receive cold end wall thickness detection data and update the phase offset of the cooling air solenoid valve of each mold cavity based on the cold end wall thickness detection data.

[0124] See Figure 3 This is the operating interface of the MES control platform. The interface is divided into a mold cavity operating condition acquisition module and a phase offset determination and asynchronous switch execution module. The interface displays the molding cycle phase, real-time pressure of the main pipe, wall thickness deviation of each mold cavity and working status. A ring phase diagram is used to represent the correspondence between the opening phase of the solenoid valve of each mold cavity and the pressure fluctuation. The table lists the operating parameters such as mold cavity number, wall thickness deviation, opening phase, phase offset, and pressure at the opening time, realizing visualization of the entire closed-loop control process.

[0125] Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the application are intended to be included within the invention.

[0126] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.

Claims

1. A method for managing an MES system based on lightweight intelligent manufacturing of glass containers, characterized in that, The lightweight intelligent manufacturing process for glass containers includes a row-type machine with a multi-cavity cooling air system. The cooling air system comprises a main pipe and branch pipes connected to each cavity. Each branch pipe is equipped with a switch-type solenoid valve, and the main pipe is equipped with a pressure sensor. A cold-end wall thickness detection device is also located at the rear of the row-type machine. The method includes the following steps: Step S1: Obtain the wall thickness deviation information of each mold cavity by analyzing the cold end wall thickness detection device according to the mold cavity number; obtain the pressure fluctuation signal collected by the main pipe pressure sensor; Step S2: Based on the wall thickness deviation information and pressure fluctuation signal, determine the opening phase offset of the cooling air solenoid valve of each mold cavity during the molding cycle; wherein, the opening phase offset of the mold cavity with lower wall thickness exceeds the limit so that the total pipe pressure value corresponding to the opening time of the solenoid valve of that mold cavity is greater than the total pipe pressure value corresponding to the opening phase offset of the mold cavity with higher wall thickness exceeds the limit, and the magnitude of the phase offset corresponds to the amplitude of the wall thickness deviation. Step S3: Control the cooling air solenoid valves of each mold cavity to perform asynchronous switching actions according to the determined phase offset. The opening phases of each mold cavity are staggered during the molding cycle. The total pipe pressure value at the opening time of each mold cavity solenoid valve is determined by the opening phase. Step S4: The MES system receives the cold end wall thickness detection data and updates the phase offset of the cooling air solenoid valve of each mold cavity based on the cold end wall thickness detection data.

2. The MES system control method based on lightweight intelligent manufacturing of glass containers according to claim 1, characterized in that, The specific steps in step S1 for acquiring the pressure fluctuation signal collected by the main pipe pressure sensor are as follows: Using the molding cycle start signal output by the row machine controller as the time reference, the pressure signal output by the main pipe pressure sensor is divided into cycles. Perform first-order differential operation on the pressure signal in each forming cycle after segmentation, mark the zero-crossing point where the differential value changes from positive to negative as the peak phase, and mark the zero-crossing point where the differential value changes from negative to positive as the trough phase; The peak phase and trough phase are arranged in the order of the forming cycle to form a pressure phase reference. At the same time, the peak pressure value sequence corresponding to each peak phase and the trough pressure value sequence corresponding to each trough phase are recorded.

3. The MES system control method based on lightweight intelligent manufacturing of glass containers according to claim 2, characterized in that, In step S2, based on the wall thickness deviation information and pressure fluctuation signal, the opening phase offset of the cooling air solenoid valve of each mold cavity during the molding cycle is determined, including: Retrieve the upper and lower boundary values ​​of the standard wall thickness band from the preset lightweight glass container process parameter library; The wall thickness deviation of each cavity is compared with the upper boundary value and the lower boundary value of the standard wall thickness band, respectively. Cavities with a wall thickness deviation value less than the lower boundary value of the standard wall thickness band are classified as cavities with lower wall thickness exceeding the limit; cavities with a wall thickness deviation value greater than the upper boundary value of the standard wall thickness band are classified as cavities with upper wall thickness exceeding the limit; and the remaining cavities are classified as cavities with normal wall thickness. Obtain the peak and trough phases within the current forming cycle from the pressure phase reference; The opening phase of the over-limit cavity with lower wall thickness is shifted towards the peak phase, and the opening phase of the over-limit cavity with higher wall thickness is shifted towards the trough phase.

4. The MES system control method based on lightweight intelligent manufacturing of glass containers according to claim 3, characterized in that, The magnitude of the phase offset in step S2 corresponds to the amplitude of the wall thickness deviation, including: Obtain the actual length and diameter of the cooling air branch pipes for each mold cavity of the row machine; The characteristic value of the cooling air branch pipe resistance of each mold cavity is determined based on the actual length and diameter; The average value of the resistance characteristic value of the cooling air branch pipes of all mold cavities is obtained as the standard resistance characteristic value; For the wall thickness exceeding the limit mold cavity, the phase offset is set to the phase difference between the current opening phase and the peak phase multiplied by the ratio of the characteristic value of the cooling air branch pipe resistance of the mold cavity to the characteristic value of the standard resistance. For mold cavities with excessive wall thickness, the phase offset is set to the phase difference between the current opening phase and the trough phase multiplied by the ratio of the characteristic value of the cooling air branch pipe resistance of the mold cavity to the characteristic value of the standard resistance.

5. The MES system control method based on lightweight intelligent manufacturing of glass containers according to claim 4, characterized in that, After obtaining the phase offset of each mold cavity, the compensation for the pressure propagation delay in the cooling air branch pipe is also included, specifically: Obtain the length information of the cooling air branch pipes for each mold cavity of the row machine; Based on the propagation speed of the cooling air in the branch pipe and the length of the branch pipe, calculate the phase delay of the pressure wave of each mold cavity from the main pipe to the solenoid valve of that mold cavity. Add the phase offset to the phase delay to obtain the phase offset after delay compensation; Arrange the opening phases of each mold cavity after delay compensation in chronological order. If the opening phase interval between adjacent mold cavities is less than the preset minimum opening phase interval, then shift the opening phase of the next mold cavity backward to the position that satisfies the minimum opening phase interval. If, after translation, the total pipe pressure value corresponding to the opening moment of the mold cavity does not meet the requirement that the total pipe pressure value corresponding to the opening moment of the lower wall thickness limit mold cavity is greater than the total pipe pressure value corresponding to the opening moment of the upper wall thickness limit mold cavity, then the opening phase of the mold cavity will be repositioned to the next phase position that meets the pressure requirement.

6. The MES system control method based on lightweight intelligent manufacturing of glass containers according to claim 1, characterized in that, Step S3, controlling the asynchronous switching action of the cooling air solenoid valves of each mold cavity according to the determined phase offset, includes: Obtain the total number of mold cavities in the row and column machine, divide the molding cycle evenly into time slots of equal length equal to the total number of mold cavities, and assign each mold cavity to the corresponding time slot according to the mold cavity number sequence; The opening time of each cavity solenoid valve is set to the start time of its corresponding time slot, and the closing time is set to the end time of that time slot; When a certain mold cavity has a phase offset, the opening time is offset by the phase offset within the corresponding time slot of the mold cavity and then used as the actual opening time. After the offset, the opening time is still within the time slot.

7. The MES system control method based on lightweight intelligent manufacturing of glass containers according to claim 6, characterized in that, The asynchronous switching of the cooling air solenoid valves for each mold cavity is also included in the process of controlling the opening timing based on real-time pressure feedback, specifically: Extract the expected main pipe pressure value corresponding to the opening phase of each mold cavity from the pressure fluctuation signal; When the original scheduled opening time of a certain mold cavity is reached, read the real-time pressure value of the main pipe pressure sensor. If the real-time pressure value is lower than the expected main pipe pressure value, the solenoid valve of the mold cavity will not be opened temporarily. The real-time pressure value will be continuously read until the real-time pressure value rises back to the expected main pipe pressure value, and then it will be opened immediately. If the real-time pressure value is higher than the expected main pipe pressure value, the solenoid valve of the mold cavity will be opened immediately.

8. The MES system control method based on lightweight intelligent manufacturing of glass containers according to claim 7, characterized in that, The asynchronous switching of the cooling air solenoid valves for each mold cavity also includes adjusting the opening and closing times based on pressure peaks, specifically: For the mold cavity with a wall thickness exceeding the limit, after the solenoid valve is opened, the real-time value of the main pipe pressure is continuously read. When the real-time pressure value rises from the pressure value corresponding to the opening time and reaches the peak and then falls back to the pressure value corresponding to the opening time, the solenoid valve is closed. For mold cavities with wall thickness exceeding the limit, if the real-time pressure value exceeds the product of the peak pressure value in the current cycle and the preset proportional factor after the solenoid valve is opened, the solenoid valve will be closed in advance; wherein, the peak pressure value is dynamically updated and determined by the maximum pressure value in the sliding window.

9. The MES system control method based on lightweight intelligent manufacturing of glass containers according to claim 1, characterized in that, Step S4 involves updating the phase offset of the cooling air solenoid valves for each mold cavity based on the cold end wall thickness detection data, including: After the MES system receives the cold end wall thickness detection data of a new batch, it calculates the wall thickness deviation change rate of each mold cavity. The wall thickness deviation change rate is the difference between the wall thickness deviation of this batch and the wall thickness deviation of the previous batch divided by the time interval between the two batches. When the direction of the wall thickness deviation change rate is consistent with the current phase offset adjustment direction, the phase offset update value is calculated based on the product of the absolute value of the change rate and the preset phase adjustment gain, and the current phase offset update value is superimposed on the phase offset of the cavity. When the direction of the wall thickness deviation change rate is opposite to the direction of the current phase offset adjustment, the phase offset of the mold cavity remains unchanged.

10. A control system for an MES system based on lightweight intelligent manufacturing of glass containers, characterized in that, The MES system control method for implementing the lightweight intelligent manufacturing of glass containers as described in claim 1, wherein the control system for the MES system based on lightweight intelligent manufacturing of glass containers comprises: The mold cavity condition acquisition module is used to acquire the wall thickness deviation information of each mold cavity according to the mold cavity number by the cold end wall thickness detection device; and to acquire the pressure fluctuation signal collected by the main pipe pressure sensor. The phase offset determination module is used to determine the opening phase offset of the cooling air solenoid valve of each mold cavity during the molding cycle based on the wall thickness deviation information and pressure fluctuation signal. Among them, the opening phase offset of the mold cavity with lower wall thickness limit makes the total pipe pressure value corresponding to the opening time of the solenoid valve of that mold cavity greater than the total pipe pressure value corresponding to the opening phase offset of the mold cavity with higher wall thickness limit, and the magnitude of the phase offset corresponds to the amplitude of the wall thickness deviation. The asynchronous switch execution module is used to control the cooling air solenoid valves of each mold cavity to perform asynchronous switching actions according to a determined phase offset. The opening phases of each mold cavity are staggered during the molding cycle, and the total pipe pressure value at the opening time of each mold cavity solenoid valve is determined by the opening phase. The phase offset update module is used to receive cold end wall thickness detection data and update the phase offset of the cooling air solenoid valve of each mold cavity based on the cold end wall thickness detection data.

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