A speed matching control method and system for a fresh stewed bird's nest production line

Abstract

This invention belongs to the field of automated control in food processing, specifically relating to a speed matching control method and system for a fresh-stewed bird's nest production line. It aims to solve the problems of individual material stewing requirements differences and the coupling between the fixed stepping rhythm of the stewing pot and the speeds of upstream and downstream equipment, leading to insufficient stewing, over-stewing, or conveying impacts in the continuous production of fresh-stewed bird's nest. The invention includes: collecting weight data and backlight projection image data at the filling station and generating a stewing time requirement index; selecting materials to enter in a reordering buffer based on the difference in the requirement index; dividing materials into groups according to preset group sizes and preset requirement mutation thresholds and calculating the target stepping cycle; adjusting the speeds of the filling and cooling sections according to the number of bottles in the buffer and the outlet release pulse interval; and updating the correction coefficient based on the outlet sampling inspection results. This invention can achieve coordinated matching between the stewing rhythm and the upstream and downstream speeds, improving stewing consistency and reducing material conveying damage after stewing.

Description

Technical Field

[0001] This invention belongs to the field of food processing automation control, specifically relating to a speed matching control method and system for a fresh stewed bird's nest production line. Background Technology

[0002] The production of freshly stewed bird's nest typically includes processes such as filling dried bird's nest, injecting liquid, sealing, stewing, cooling, and conveying. Due to the irregular shape of the raw bird's nest, there are differences between different bottles of material in terms of strand thickness, density, initial moisture content, water absorption and expansion speed, and sedimentation state. Even if the filling weight is similar, the stewing time required for different bottles of material to reach a stable cooked state may also be different.

[0003] Existing fresh-stewed bird's nest production lines mostly use fixed-cycle walking beam stewing kettles, and achieve equipment linkage through conveyor belt encoder following, buffer station start / stop control, or upstream and downstream speed cascading. This type of method usually treats the filling section, stewing section, and cooling section as a continuously coupled conveying system, making it difficult to simultaneously meet the requirements of filling efficiency, stewing consistency, and low-impact conveying of stewed materials. When the stewing kettle uses a fixed walking cycle, materials with high stewing requirements may be under-stewed, while materials with low stewing requirements may be over-stewed.

[0004] Furthermore, even when estimating the stewing requirements of a single bottle of material at the filling end through weighing or visual methods, it is difficult to provide different residence times for each bottle of material because the trays in the walking stewing kettle usually advance synchronously. Therefore, a control method is needed that can use filling end detection data to determine the stewing requirements of a single bottle and achieve coordinated matching of the production line through reordering, grouping and stepping, decoupling of upstream and downstream speeds, and outlet feedback correction. Summary of the Invention

[0005] This invention aims to solve the problem that in the continuous production of fresh stewed bird's nest, the stewing time requirements of different individual bottles of materials vary, and the stepping stone stewing kettle operates with a uniform stepping rhythm, which makes it difficult to match the stewing requirements of individual bottles of materials with the operating rhythm of the production line, as well as the problem of unstable speed connection between the filling section, stewing section and cooling section. The invention provides a speed matching control method and system for fresh stewed bird's nest production line.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: The first aspect of this invention provides a speed matching control method for a freshly stewed bird's nest production line, comprising: Weight data and backlight projection image data of a single bottle of material are collected at the filling station. Weight response features and solid projection features are extracted to form a parameter set. The stewing time requirement index is obtained by interpolation based on a preset mapping table. In the reordering buffer zone after filling and capping and before the stewing inlet, the difference in stewing time requirement index between each bottle of material and the previous material entering the stewing pot is compared, and the material with the smallest difference is sent into the stewing pot. The materials continuously entering the stewing pot are divided into material groups according to the preset group size and preset demand mutation threshold, and a correction coefficient is bound. The corrected stewing demand is determined based on the maximum stewing time demand index and correction coefficient of each material group. The remaining step cycle demand is determined by combining the cumulative stewing time of each bottle in the pot and the remaining number of steps. The maximum value of the remaining step cycle demand of each bottle in the pot is taken as the target step cycle. After being corrected by the preset step cycle upper and lower limits, it is written into the step trigger timer. Adjust the target speed of the filling section according to the current number of bottles in the reordering buffer, and adjust the target speed of the cooling section according to the pulse interval of material release at the outlet of the stewing kettle; The correction coefficients bound to newly created material groups are updated based on the results of material sampling inspections after stewing.

[0007] In one possible implementation, weight response features and solid projection features are extracted to form a parameter set, and the stewing time requirement index is obtained by interpolation based on a preset mapping table, including: Obtain the empty bottle tare weight, filter the weight data and determine the baseline weight fluctuation range, weight change rate, static observation fluctuation energy and end weight. Determine the weight response start time based on the baseline weight fluctuation range, determine the weight change peak time based on the weight change rate, determine the weight response time parameter based on the weight response start time and weight change peak time, determine the sedimentation competition parameter based on the static observation fluctuation energy, and determine the total mass of material after filling based on the end weight and empty bottle tare weight. The solid object projection is separated frame by frame from the backlight projection image data to obtain the solid object projection area and the vertical distribution dispersion. The solid object projection area change parameters and the area ratio of the last static observation segment are determined based on the temporal change of the solid object projection area. The stretching stabilization time parameters are determined based on the solid object projection area change parameters and the vertical distribution dispersion. The parameters are: weight response time, sedimentation competition, total mass of material after filling, change in projected area of ​​solids, expansion stabilization time, and area ratio of the final static observation segment. The nearest neighbor record with the normalized distance to the parameter set is found in the preset mapping table. The stewing time requirement index corresponding to the nearest neighbor record is weighted and interpolated according to the normalized distance between each neighbor record and the parameter set to obtain the stewing time requirement index of the current bottle material.

[0008] In one possible implementation, when the weight data or backlight projection image data does not meet the preset complete acquisition conditions, the corresponding single bottle of material is identified as an abnormal acquisition bottle. The most recently preset number of successfully output stewing time requirement indices are read, the median of the read stewing time requirement indices is calculated, and the alternative stewing time requirement index for the abnormal acquisition bottle is obtained. The alternative stewing time requirement index is then used as the stewing time requirement index for the abnormal acquisition bottle for material selection in the reordering buffer.

[0009] In one possible implementation, comparing the difference in cooking time requirement index between each bottle of material and the material that previously entered the stewing pot, and sending the material with the smallest difference into the stewing pot includes: Read the waiting time and stewing time requirement index of each bottle of material in the reordering buffer, calculate the difference in stewing time requirement index between each bottle of material and the previous material entering the stewing pot, determine the material with the smallest difference as the material to be entered, and when there are multiple materials with the smallest difference, determine the material with the largest waiting time as the material to be entered. When there are obstructing materials between the material to be introduced and the outlet of the reordering buffer, the temporary avoidance order is determined according to the difference in stewing time requirement index between each obstructing material and the material to be introduced. The obstructing materials are moved into the temporary storage bottle according to the temporary avoidance order. After the material to be introduced is sent into the stewing pot, the obstructing materials are then backfilled into the empty buffer bottle.

[0010] In one possible implementation, the materials continuously entering the stewing pot are divided into material groups according to a preset group size and a preset demand mutation threshold, and a correction coefficient is attached. Determining the target step cycle includes: The preset initial correction factor is used as the initial current effective correction factor, and the current effective correction factor is replaced by the correction factor updated based on the sampling results of the materials after stewing. The material group boundary is determined by comparing the difference in stewing time requirement index between the material currently entering the stewing pot and the material previously entering the stewing pot with the preset requirement mutation threshold, and by comparing the number of bottles to be divided into material groups with the preset group size. The current effective correction coefficient is then bound to the newly created material group. Update the maximum stewing time requirement index of the material group to which the material belongs in the pot, and determine the corrected stewing requirement of the corresponding material group by multiplying the maximum stewing time requirement index with the correction coefficient bound to the corresponding material group. For each bottle of material in the autoclave with a remaining number of steps greater than zero, the difference between the corrected stewing requirement of the corresponding material group and the corresponding cumulative stewing time is limited to not less than zero. The limited difference is divided by the corresponding remaining number of steps to obtain the remaining step cycle requirement of each bottle of material in the autoclave, and the maximum value of the remaining step cycle requirement of each bottle of material in the autoclave is selected as the target step cycle.

[0011] In one possible implementation, writing to the step trigger timer after correction by preset step period upper and lower limits includes: The target step cycle is restricted to between the preset minimum allowable step cycle and the preset maximum allowable step cycle to obtain the corrected target step cycle; When the corrected target step cycle is different from the current execution step cycle, the intermediate step cycle is determined based on the current execution step cycle, the corrected target step cycle, and the preset transition step number. The intermediate step cycle is corrected according to the acceleration and deceleration boundary of the stewing pot stepping mechanism and then written into the step trigger timer. When the corrected target step cycle is the same as the current execution step cycle, the corrected target step cycle is written into the step trigger timer. After each actual step is completed, the actual step cycle is added to the cumulative cooking time of each bottle of material in the reactor, the remaining number of steps for each bottle of material in the reactor is reduced by one, and the remaining step cycle requirement and target step cycle for each bottle of material in the reactor are re-determined.

[0012] In one possible implementation, adjusting the target speed of the filling section based on the current number of bottles in the reordering buffer includes: Get the current number of bottles in the reordering buffer, and compare the current number of bottles in the reordering buffer with the preset lower limit number of bottles and the preset upper limit number of bottles respectively; When the current number of bottles in the reordering buffer is lower than the preset lower limit, the target speed of the filling section is increased by a preset speed step; when the current number of bottles in the reordering buffer is higher than the preset upper limit, the target speed of the filling section is decreased by a preset speed step; when the current number of bottles in the reordering buffer is greater than or equal to the preset lower limit and less than or equal to the preset upper limit, the target speed of the filling section is maintained. After performing low-pass filtering and acceleration boundary verification on the target speed of the filling section, the output is sent to the filling section conveyor controller.

[0013] In one possible implementation, adjusting the target speed of the cooling section based on the pulse interval of material release from the cooking vessel outlet includes: Each time material is ejected from the stewing pot, the material release pulse at the outlet of the stewing pot is collected, and the average release interval is calculated for the time interval between adjacent material release pulses at the outlet of the stewing pot within a preset sliding window. The target speed of the cooling section is obtained by dividing the center distance between adjacent bottle positions in the cooling section by the average release interval. The target speed of the cooling section is then low-pass filtered and output to the cooling section conveyor controller.

[0014] In one possible implementation, updating the correction coefficient bound to the subsequently newly created material group based on the material sampling results after stewing includes: Images of the stewed material were collected at preset sampling intervals, and the outlet area ratio and outlet sedimentation fluctuation parameters were extracted. The outlet area ratio and outlet sedimentation fluctuation parameters were then compared with the corresponding preset target intervals. When at least one of the export area ratio and export settlement fluctuation parameters is lower than the lower limit of the corresponding preset target range for a consecutive preset number of times, the correction coefficient is increased; when neither the export area ratio nor the export settlement fluctuation parameter is lower than the lower limit of the corresponding preset target range, and at least one parameter is higher than the upper limit of the corresponding preset target range for a consecutive preset number of times, the correction coefficient is decreased; when the conditions for increasing or decreasing the correction coefficient are not met, the correction coefficient is maintained. When increasing or decreasing the correction coefficient, the correction step size is determined based on the deviation of the export area ratio and the export settlement fluctuation parameter from the corresponding preset target range. A preset upper limit constraint is applied to the correction step size, and the correction coefficient is increased or decreased according to the correction step size. Bind the updated correction factor to the newly created material group.

[0015] A second aspect of the present invention provides a speed matching control system for a freshly stewed bird's nest production line, comprising: The parameter acquisition and index calculation module is used to collect the weight data and backlight projection image data of a single bottle of material at the filling station, extract the weight response features and solid projection features to form a parameter set, and obtain the stewing time requirement index based on the preset mapping table interpolation. The reordering module is used in the reordering buffer zone after filling and capping and before the stewing inlet. It compares the difference in stewing time requirement index between each bottle of material and the material that entered the stewing pot the previous time, and sends the material with the smallest difference into the stewing pot. The step cycle control module is used to divide the materials continuously entering the stewing pot into material groups according to the preset group size and preset demand mutation threshold, and bind correction coefficients. Based on the maximum stewing time demand index and correction coefficient of each material group, the corrected stewing demand is determined. The remaining step cycle demand is determined by combining the cumulative stewing time of each bottle in the pot and the remaining number of steps. The maximum value of the remaining step cycle demand of each bottle in the pot is taken as the target step cycle. After being corrected by the preset step cycle upper and lower limits, it is written into the step trigger timer. The speed matching control module is used to adjust the target speed of the filling section according to the current number of bottles in the reordering buffer, and to adjust the target speed of the cooling section according to the pulse interval of material release at the outlet of the stewing kettle. The feedback correction module is used to update the correction coefficients bound to newly created material groups based on the results of material sampling inspections after stewing.

[0016] The beneficial effects of this invention are: This invention collects weight data and backlight projection image data of individual bottle materials at the filling station, extracts weight response time parameters, sedimentation competition parameters, total mass of materials after filling, solid projection area change parameters, expansion stabilization time parameters, and static observation end area ratio, and obtains a stewing time requirement index based on a preset mapping table, so that the stewing cycle control can reflect the differences of different individual bottle materials in terms of weight response, solid expansion, sedimentation, and filling state.

[0017] This invention sets up a reordering buffer zone after filling and capping and before the stewing inlet, and compares the difference in stewing time requirement index between each bottle of material and the material that entered the stewing pot the previous time. Materials with smaller differences are given priority to enter the stewing pot, which helps to reduce the sudden change in stewing requirements between materials that enter the stewing pot continuously, and provides a more stable material requirement sequence for subsequent material grouping and step cycle control.

[0018] This invention divides materials into groups according to preset group size and preset demand mutation threshold, determines the corrected stewing demand based on the maximum stewing time demand index and correction coefficient of each material group, and then determines the remaining step cycle demand by combining the cumulative stewing time of each bottle of material in the pot and the remaining number of steps. The target step cycle is determined by the maximum remaining step cycle demand, so that the determination of the step cycle can simultaneously take into account the actual stewing time that different materials in the pot have experienced and the subsequent remaining operation process, reducing the risk of under-stewing or over-stewing caused by determining the rhythm solely based on a fixed step cycle or the current newly added material.

[0019] This invention adjusts the target speed of the filling section based on the current number of bottles in the reordering buffer, and adjusts the target speed of the cooling section based on the pulse interval of material release at the outlet of the stewing kettle. This allows the material supply upstream of the stewing kettle and the material conveying downstream to be adjusted according to the corresponding local operating state, which helps to reduce material accumulation, material interruption and speed fluctuations caused by changes in the cycle time between the filling section, stewing section and cooling section, and improves the speed matching stability in the continuous production process.

[0020] This invention involves sampling and inspecting the materials after stewing, and updating the correction coefficients bound to the newly built material groups based on the proportion of the outlet area and the outlet settling fluctuation parameters. This allows the status of the outlet materials to be fed back to the corrected stewing requirements and target step cycle determination process of the subsequent material groups, thereby adapting to changes in raw material batches, filling status, and production operating conditions, and improving the stewing consistency and cycle control stability in the continuous production process of fresh stewed bird's nest. Attached Figure Description

[0021] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1This is the main flowchart of the speed matching control method for a freshly stewed bird's nest production line provided in this embodiment of the invention; Figure 2 This is a flowchart of the stewing time requirement index generation and collection anomaly handling process provided in this embodiment of the invention; Figure 3 This is a flowchart of the reordering buffer material selection and blocking bottle avoidance process provided in this embodiment of the invention. Figure 4 This is a structural block diagram of the speed matching control system for the fresh stewed bird's nest production line provided in an embodiment of the present invention. Detailed Implementation

[0022] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be noted that, for ease of description, only the parts relevant to the present invention are shown in the accompanying drawings.

[0023] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] The first embodiment of this invention proposes a speed matching control method for a fresh stewed bird's nest production line, comprising the following steps: S10: Collect weight data and backlight projection image data of single bottle material at the filling station, extract weight response features and solid projection features to form a parameter set, and interpolate based on a preset mapping table to obtain the stewing time requirement index. S20: In the reordering buffer zone after filling and capping and before the stewing inlet, compare the difference in stewing time requirement index between each bottle of material and the material that entered the stewing pot the previous time, and send the material with the smallest difference into the stewing pot. S30: Divide the materials continuously entering the stewing pot into material groups according to the preset group size and preset demand mutation threshold, and bind correction coefficients. Determine the corrected stewing demand based on the maximum stewing time demand index and correction coefficient of each material group. Combine the cumulative stewing time of each bottle in the pot and the remaining number of steps to determine the remaining step cycle demand. Take the maximum value of the remaining step cycle demand of each bottle in the pot as the target step cycle. After correction by the preset step cycle upper and lower limits, write it into the step trigger timer. S40: Adjust the target speed of the filling section according to the current number of bottles in the reordering buffer, and adjust the target speed of the cooling section according to the pulse interval of material release at the outlet of the stewing kettle; S50: Update the correction coefficient bound to the newly created material group based on the sampling results of the material after stewing.

[0025] To more clearly illustrate the speed matching control method for a fresh stewed bird's nest production line according to the present invention, the steps in this embodiment will be described in detail below with reference to the accompanying drawings.

[0026] S10: Collect weight data and backlight projection image data of single bottle materials at the filling station, extract weight response features and solid projection features to form a parameter set, and interpolate based on a preset mapping table to obtain the stewing time requirement index.

[0027] like Figure 2 As shown, in this embodiment, step S10 includes: Step S11: Filter the weight data, determine the weight response start time based on the baseline weight fluctuation range, determine the weight change peak time based on the weight change rate, obtain the weight response time parameter based on the weight response start time and the weight change peak time, determine the sedimentation competition parameter based on the static observation of the fluctuation energy, and determine the total mass of the material after filling based on the end weight and the empty bottle tare weight. Step S12: Separate the solid object projection frame by frame from the backlight projection image data, and determine the solid object projection area change parameters, stretching stabilization time parameters, and static observation end area ratio based on the solid object projection area change and vertical distribution dispersion. Step S13: The weight response time parameter, sedimentation competition parameter, total mass of material after filling, solid projection area change parameter, expansion stabilization time parameter, and static observation end area ratio are combined into a parameter set. The nearest neighbor record with the normalized distance to the parameter set is found in the preset mapping table. The stewing time requirement index corresponding to the neighbor record is weighted and interpolated according to the normalized distance between each neighbor record and the parameter set to obtain the stewing time requirement index of the current bottle material. Step S14: When the weight data or backlight projection image data does not meet the preset complete acquisition conditions, the corresponding single bottle material is identified as an abnormal acquisition bottle. The most recently preset number of successfully output stewing time requirement indices are read, the median of the read stewing time requirement indices is calculated, and the alternative stewing time requirement index of the abnormal acquisition bottle is obtained. The alternative stewing time requirement index is used as the stewing time requirement index of the abnormal acquisition bottle for material selection in the reordering buffer.

[0028] Specifically, the filling station is equipped with a dynamic weighing unit and a backlit image acquisition unit. The dynamic weighing unit is located below the filling nozzle or at a short-distance detection position after filling, and its sampling frequency is set to no less than 1kHz. The backlit image acquisition unit includes a global shutter industrial camera, an infrared cutoff filter, and a low-angle LED backlight, with its acquisition frame rate set to no less than 20fps. The weighing sensor and the industrial camera are connected to the same edge computing node. When the filling valve opens, a trigger signal is output by the PLC, and the edge computing node starts continuous acquisition based on the trigger signal. The acquisition window is set, for example, from 0.5s before the trigger to 8s after the trigger, thereby obtaining the weight data and backlit projected image data corresponding to the same single bottle material.

[0029] For step S11, during the single-bottle filling process, the weight data is first subjected to sliding mean filtering, median filtering, or first-order low-pass filtering to reduce transient interference caused by liquid surface vibration, bottle shaking, and conveyor mechanism vibration. Weight sampling values ​​are read within a preset time before the filling valve opens, and a baseline weight fluctuation range is determined based on the average value and fluctuation range of the weight sampling values.

[0030] After filling begins, when the filtered weight value exceeds the baseline weight fluctuation range for a preset number of consecutive sampling points, the sampling time that first meets this condition is determined as the weight response start time. Starting from the weight response start time, the weight change rate is determined based on adjacent weight sampling values ​​and corresponding sampling time intervals, and the first local positive peak value is searched for. The sampling time corresponding to this local positive peak value is determined as the weight change peak time.

[0031] The time interval between the start of the weight response and the peak of the weight change is defined as the weight response time parameter. The weight response time parameter characterizes the time it takes for the weight signal of the current bottled material to stabilize and for the rate of weight change to reach its peak during the injection process.

[0032] Before production, empty bottle filling calibration is performed, and the weight fluctuation energy generated by the mechanical vibration of the production line itself within a preset frequency band is recorded to obtain the baseline fluctuation energy. For the current bottle material during normal production, the static observation period after filling is extracted, and the fluctuation of the weight sample value relative to the weight mean during this period is squared and accumulated, or the weight fluctuation within the preset frequency band is statistically analyzed to obtain the static observation fluctuation energy.

[0033] The settling competition parameter is obtained by dividing the difference between the static observed fluctuation energy of the current bottle material and the baseline fluctuation energy by the difference between the preset maximum allowable fluctuation energy and the baseline fluctuation energy. The settling competition parameter is then limited to between 0 and 1. The larger the settling competition parameter, the more obvious the weight fluctuation caused by the displacement and settling of solids inside the bottle during the static observation stage after filling.

[0034] The final weight is the average of a preset number of weight samples taken at the end of the static observation period. The empty bottle tare weight corresponding to the current bottle material is obtained, and the final weight is subtracted from the empty bottle tare weight to obtain the total mass of the material after filling. The total mass of the material after filling includes both solids and liquid in the bottle, and is used to characterize the total amount of material actually carried by a single bottle.

[0035] For step S12, bottle region localization, background subtraction, threshold segmentation and connected region filtering are performed frame by frame on the backlight projection image data to obtain the solid object projection region in each frame image, and the corresponding solid object projection area is calculated.

[0036] The rate of change of the projected area of ​​the solid is determined based on the projected area of ​​the solid in adjacent image frames and the acquisition time interval. The maximum value of the rate of change of the projected area of ​​the solid is searched during the liquid injection stage, and this maximum value is used as the parameter of the projected area change of the solid to characterize the expansion rate of the projected area of ​​the bird's nest after liquid injection.

[0037] The effective observation area inside the bottle is divided into a predetermined number of height sub-regions along the height direction of the bottle, for example, 12 height sub-regions. The projected area of ​​the solid material in each height sub-region is calculated, and the vertical distribution dispersion is determined based on the dispersion of the projected area of ​​the solid material in each height sub-region relative to the overall average value. The greater the vertical distribution dispersion, the more uneven the distribution of the solid material along the height direction of the bottle.

[0038] After the rate of change of the projected area of ​​the solid object reaches its maximum value, the rate of change of the projected area and the vertical distribution dispersion are continuously monitored. When the rate of change of the projected area of ​​the solid object is lower than a preset proportion of the maximum rate of change of the projected area of ​​the solid object within a continuous preset observation period, and the relative change of the vertical distribution dispersion within the observation period is lower than a preset stability threshold, the moment when the above conditions are first met is determined as the stretching stability moment. The time interval between the moment when the rate of change of the projected area of ​​the solid object reaches its maximum value and the stretching stability moment is determined as the stretching stability time parameter.

[0039] Record the projected area of ​​solids at the initial stage of injection and the projected area of ​​solids at the end of static observation. Divide the projected area of ​​solids at the end of static observation by the projected area of ​​solids at the initial stage of injection to obtain the area ratio at the end of static observation.

[0040] Therefore, the weight response time parameter, sedimentation competition parameter, total mass of material after filling, solids projected area change parameter, expansion stabilization time parameter, and static observation area ratio are combined to form a six-dimensional parameter set corresponding to the current bottle material.

[0041] For step S13, the preset mapping table includes multiple calibrated records. Each calibrated record includes at least the six parameters mentioned above and the corresponding stewing time requirement index. The preset mapping table is established through pre-production process experiments. Sample bottles covering different batches, strand states, initial moisture content, and filling states of bird's nest in normal production are selected. The six parameters corresponding to each sample bottle are obtained in the manner described above. The stewing time required for each sample bottle to reach the target maturation state at the preset stewing temperature is tested. The stewing time is used as the calibrated stewing time requirement index for the corresponding sample bottle.

[0042] When applying online, the six parameters of the current bottle material and the corresponding parameters in each calibrated record are scaled and normalized, and the parameter set of the current bottle material is calculated and compared with the first parameter. Normalized distance between labeled records : ; In the formula, This indicates the parameter set of the current bottle material and the first... The normalized distance between the labeled records; This represents the first parameter in the parameter set of the current bottle material. Each parameter value; Indicates the first The first item in the already marked record Each parameter value; Indicates the first Each parameter corresponds to a preset normalization scale; Indicates the parameter index in the six-dimensional parameter set; This indicates that a record number has been assigned.

[0043] Select the preset number in ascending order of normalization distance. The nearest records are counted, and weighted interpolation is performed according to the principle that the smaller the normalized distance, the greater the weight of the corresponding nearest record, to obtain the stewing time requirement index of the current bottle material. : ; In the formula, This indicates the required cooking time index for the current bottled material; This indicates the number of neighboring records involved in the weighted interpolation; Indicates the first The index of calibrated stewing time requirement corresponding to each adjacent record; This indicates the parameter set of the current bottle material and the first... Normalized distance between neighboring records; This represents a preset positive number used to avoid calculation errors caused by the normalized distance being zero; This indicates the sequence number of the nearest record that participated in the weighted interpolation.

[0044] For example, in a single-bottle material acquisition window, the weight data processing yields a baseline average weight of 125.34g, a baseline standard deviation of 0.05g, a weight response start time of 0.18s, and a weight change peak time of 0.42s, therefore the weight response time parameter is 0.24s; the backlight projection image data processing yields a maximum solid projection area change rate of 2410px. 2 / s, with a stretching stabilization time parameter of 2.65s.

[0045] The baseline fluctuation energy obtained from the empty bottle filling calibration is 0.0008, the static observation fluctuation energy of the current bottle material is 0.0032, and the preset maximum allowable fluctuation energy is 0.005. Therefore, the sedimentation competition parameter is approximately 0.57; the projected area of ​​solids in the initial stage of filling is 780px. 2 The projected area of ​​the solid object at the end of the static observation is 3220px. 2 If the area ratio of the final section observed at rest is approximately 4.13, and the final weight is 245.6g, and the tare weight of the empty bottle is 100.0g, then the total mass of the material after filling is 145.6g.

[0046] The above six parameters form the parameter set for the current bottle material. A preset number of neighboring records are searched in the preset mapping table, and weighted interpolation yields a stewing time requirement index of 48.2 minutes for the current bottle material. This 48.2 minutes represents the stewing time requirement corresponding to the current bottle material state when the preset mapping table was established, and does not mean that the current bottle material will be stewed independently for a fixed 48.2 minutes after entering the production line. Subsequent step S30 combines the stewing time requirement index with the material group, cumulative stewing time, and remaining step count to convert it into the actual target step cycle executed by the stewing pot.

[0047] For step S14, when there are consecutive missing weight data points, the weight data cannot correspond to the bottle label, the backlight projection image is abnormally exposed, the bottle is blocked by other objects, or the number of effective image frames is less than the preset number, it is determined that the corresponding single bottle material does not meet the preset complete collection conditions, and the single bottle material is determined as an abnormal collection bottle.

[0048] For bottles with abnormal collection, read the stewing time requirement index of the 5 most recent or 7 most recent bottles that have been output normally, calculate the median of the read stewing time requirement index, and determine the median as the alternative stewing time requirement index for bottles with abnormal collection.

[0049] For example, the stewing time requirement indices for the five most recent normal samples are 47.8 min, 48.3 min, 48.0 min, 48.5 min, and 48.1 min, respectively. Arranged from smallest to largest, these indices are 47.8 min, 48.0 min, 48.1 min, 48.3 min, and 48.5 min, with a median of 48.1 min. Therefore, 48.1 min is determined as the alternative stewing time requirement index for the abnormal sample, and this alternative stewing time requirement index is used as the stewing time requirement index for the abnormal sample in the subsequent material selection in the reordering buffer.

[0050] S20: In the reordering buffer zone after filling and capping and before the stewing inlet, compare the difference in stewing time requirement index between each bottle of material and the material that entered the stewing pot the previous time, and send the material with the smallest difference into the stewing pot.

[0051] like Figure 3 As shown, in this embodiment, step S20 includes: Step S21: Read the waiting time and stewing time requirement index of each bottle of material in the reordering buffer, calculate the difference in stewing time requirement index between each bottle of material and the previous material entering the stewing pot, and determine the material with the smallest difference as the material to be entered; when there are multiple materials with the smallest difference, determine the material with the largest waiting time as the material to be entered. Step S22: When there are obstructing materials between the material to be entered and the outlet position of the reordering buffer, the temporary avoidance order is determined according to the difference in stewing time requirement index between each obstructing material and the material to be entered. The obstructing materials are moved into the temporary storage bottle according to the temporary avoidance order. After the material to be entered is sent into the stewing pot, the obstructing materials are then backfilled into the empty buffer bottle.

[0052] Specifically, the reordering buffer is located after filling and capping, and before the stewing inlet. The reordering buffer includes multiple buffer bottle positions, two or more independently startable and stopable conveyor sections, a conveyor mechanism capable of partial reverse operation, a bottle-shifting mechanism, temporary bottle storage positions, and an outlet positioning sensor. Each buffer bottle position is assigned a corresponding bottle position identifier, enabling the central controller to maintain the correspondence between the bottle identifier, the stewing time requirement index, the entry time into the buffer, and the current buffer bottle position.

[0053] In one specific implementation, the reordering buffer has 24 buffer positions. After the stewing pot completes one step and releases the inlet receive bit, the central controller reads each bottle of material that can be retrieved from the reordering buffer and uses the stewing time requirement index of the material that entered the stewing pot last as a comparison benchmark.

[0054] For example, the cooking time requirement index of the material that previously entered the stewing pot was 47.8 min. The cooking time requirement indices of the currently available materials are 47.5 min, 48.0 min, 49.1 min, 48.5 min, 47.7 min, and 47.9 min, respectively. The differences between these indices and 47.8 min are 0.3 min, 0.2 min, 1.3 min, 0.7 min, 0.1 min, and 0.1 min, respectively. Therefore, the materials corresponding to 47.7 min and 47.9 min are the materials with the smallest differences. If the waiting times for the two materials are 32 s and 46 s, respectively, then the material with a waiting time of 46 s and a cooking time requirement index of 47.9 min is determined to be the material to be entered.

[0055] When there is no obstructing material between the material to be entered and the outlet position of the reordering buffer, the corresponding conveying section or bottle-dispensing mechanism is controlled to send the material to be entered to the outlet position and into the stewing pot.

[0056] When there are obstructing materials between the material to be entered and the exit position of the reordering buffer, calculate the difference in stewing time requirement index between each obstructing material and the material to be entered, and determine the temporary avoidance order according to the difference from small to large; for obstructing materials with the same stewing time requirement index difference, determine the order according to the waiting time from long to short.

[0057] For example, if the cooking time requirement index of the material to be introduced is 47.9 min, and there are three obstructing materials between it and the outlet of the reordering buffer, with cooking time requirement indices of 48.0 min, 48.6 min, and 49.2 min respectively, corresponding to waiting times of 35 s, 28 s, and 40 s respectively. The differences in cooking time requirement indices between the three obstructing materials and the material to be introduced are 0.1 min, 0.7 min, and 1.3 min respectively. Therefore, the temporary avoidance order is determined according to the order of the material corresponding to 48.0 min, the material corresponding to 48.6 min, and the material corresponding to 49.2 min, and the three obstructing materials are moved into the temporary storage bottle according to this order. After the material to be introduced enters the cooking pot, the obstructing materials in the temporary storage bottle are then returned to the empty buffer bottle.

[0058] When new material enters the reordering buffer from the filling and capping section, the central controller associates the bottle identifier of the new material and the stewing time requirement index determined in step S10 with the corresponding buffer bottle position. If the new material is a bottle with abnormal collection, it is associated with the alternative stewing time requirement index determined in step S14.

[0059] S30: Divide the materials continuously entering the stewing pot into material groups according to the preset group size and preset demand mutation threshold, and bind correction coefficients. Determine the corrected stewing demand based on the maximum stewing time demand index and correction coefficient of each material group. Determine the remaining step cycle demand by combining the cumulative stewing time of each bottle in the pot and the remaining number of steps. Take the maximum value of the remaining step cycle demand of each bottle in the pot as the target step cycle. After correction by the preset step cycle upper and lower limits, write it into the step trigger timer.

[0060] In this embodiment, step S30 includes: Step S31: Use the preset initial correction coefficient as the initial current effective correction coefficient, and replace the current effective correction coefficient with the correction coefficient updated according to the material sampling inspection results after stewing; determine the material group boundary according to the comparison result of the stewing time demand index difference between the current material entering the stewing pot and the previous material entering the stewing pot and the preset demand mutation threshold, and the comparison result of the number of bottles to be divided into material groups and the preset group size, and bind the current effective correction coefficient to the newly created material group; Step S32: Update the maximum stewing time requirement index of the material group to which the material in the pot belongs. The product of the maximum stewing time requirement index and the correction coefficient bound to the corresponding material group is determined as the corrected stewing requirement of the corresponding material group. For each bottle of material in the pot with a remaining number of steps greater than zero, the difference between the corrected stewing requirement of the corresponding material group and the corresponding cumulative stewing time is restricted to not less than zero. The restricted difference is divided by the corresponding remaining number of steps to obtain the remaining step cycle requirement of each bottle of material in the pot. The maximum value among the remaining step cycle requirements of each bottle of material in the pot is selected as the target step cycle. Step S33: Limit the target stepping cycle to between the preset minimum allowable stepping cycle and the preset maximum allowable stepping cycle to obtain the corrected target stepping cycle; when the corrected target stepping cycle is different from the currently executed stepping cycle, determine the intermediate stepping cycle based on the currently executed stepping cycle, the corrected target stepping cycle, and the preset transition step number; correct the intermediate stepping cycle based on the drive acceleration / deceleration boundary of the stewing pot stepping mechanism and write it into the stepping trigger timer; when the corrected target stepping cycle is the same as the currently executed stepping cycle, write the corrected target stepping cycle into the stepping trigger timer; after each actual stepping is completed, add the actual executed stepping cycle to the cumulative stewing time of each bottle of material in the pot, decrement the remaining stepping count of each bottle of material in the pot by one, and re-determine the remaining stepping cycle requirement and target stepping cycle of each bottle of material in the pot.

[0061] Specifically, the stewing pot employs a multi-pallet synchronous stepping conveyor structure. After entering through the stewing inlet, the material bottle gradually traverses the complete stewing path with the pallets and exits through the stewing outlet. Because all pallets within the stewing pot are synchronously advanced by the same stepping mechanism, each actual stepping cycle simultaneously affects all currently stored materials.

[0062] For step S31, when the production line starts running and there are no post-cooking material sampling results yet, the preset initial correction coefficient is determined as the current effective correction coefficient. After step S50 updates the correction coefficient based on the post-cooking material sampling results, starting from the next newly created material group, the updated correction coefficient is replaced with the new current effective correction coefficient. Existing material groups continue to retain the correction coefficient bound at the time of creation.

[0063] The preset group size is, for example, 6 bottles, and the preset demand mutation threshold is, for example, 1.0 min. When there is no material group to be divided, the material currently entering the stewing pot is taken as the first bottle of the new material group, and the current effective correction coefficient is bound to the new material group.

[0064] When there are material groups to be divided, calculate the difference in cooking time requirement index between the material currently entering the stewing pot and the material that entered the stewing pot previously. If the difference in cooking time requirement index exceeds a preset requirement mutation threshold, determine the boundary of the previous material group and establish a new material group based on the material currently entering the stewing pot; if the difference in cooking time requirement index does not exceed the preset requirement mutation threshold, add the material currently entering the stewing pot to the material group to be divided. When the number of bottles in the material group to be divided reaches the preset group size, determine the boundary of that material group.

[0065] For example, the cooking time requirements for the first five bottles in the material group to be divided are 47.9 min, 48.0 min, 47.7 min, 48.1 min, and 47.8 min, respectively. The cooking time requirement for the sixth bottle is 48.2 min. The difference in cooking time requirement between the sixth bottle and the previous bottle entering the cooking pot is 0.4 min, which does not exceed 1.0 min. Therefore, the sixth bottle is added to the material group to be divided. After adding the sixth bottle, the number of bottles in the material group reaches the preset group size of 6, thus defining the boundary of this material group. The maximum cooking time requirement for this material group is 48.2 min.

[0066] If the cooking time requirement index of the material that subsequently enters the stewing pot is 49.5 min, and the difference between its cooking time requirement index and that of the material that entered the stewing pot previously (48.2 min) is 1.3 min, which is more than 1.0 min, then the material group boundary of the previous material group is determined, and a new material group is established with the material corresponding to 49.5 min. At the same time, the current effective correction coefficient is bound to the newly established material group.

[0067] As the materials enter the stewing pot, the maximum stewing time requirement index for the corresponding material group is continuously updated. The maximum stewing time requirement index for the material group is multiplied by the correction coefficient bound to that material group to obtain the corrected stewing requirement for the corresponding material group.

[0068] For example, the maximum stewing time requirement index for the aforementioned material group is 48.2 min, and the correction factor for this material group is 1.00. Therefore, the corresponding corrected stewing time requirement is 48.2 min, or 2892 s. The maximum stewing time requirement index for another material group is 49.0 min, and the correction factor is 1.01. Therefore, the corresponding corrected stewing time requirement is 49.49 min, or 2969.4 s.

[0069] For step S32, the central controller establishes a record in the cooking pot for each bottle of material entering the cooking pot. The record in the cooking pot includes at least the bottle identifier, the material group to which it belongs, the cumulative cooking time, and the remaining number of steps.

[0070] When material first enters the stewing pot, the cumulative stewing time for the corresponding material is initialized to 0, and the remaining number of steps is initialized to the total number of steps required to move from the stewing inlet to the stewing outlet. For example, if the complete stewing path in the stewing pot corresponds to 240 steps, then the remaining number of steps for the newly entered material is initialized to 240.

[0071] Each time a step is actually completed, the time corresponding to the actual step cycle is added to the total cooking time of all materials still in the stewing pot, and the remaining step count for each bottle of material in the pot is decremented by 1. When the remaining step count for a bottle of material in the pot is reduced to 0, it is determined that the bottle of material has completed the complete stewing path, and the bottle of material is removed from the in-pot operation record.

[0072] Before calculating the remaining step cycle demand, the corrected stewing demand and cumulative stewing time are converted to seconds. For the first... Bottled material in reactor, its remaining step cycle requirement for: ; In the formula, Indicates the first The remaining step cycle requirement for the bottled material in the reactor; Indicates the first The corrected stewing requirements for the material group to which the bottle belongs in the kettle; Indicates the first The cumulative cooking time of the bottled material since it entered the cooking pot; Indicates the first The remaining number of steps required to move the material in the bottle from its current location to the cooking outlet; This indicates the material serial number in the reactor.

[0073] When the cumulative stewing time Meets or exceeds the calibrated stewing requirements At that time, the corresponding remaining step cycle requirement Set to 0; when the cumulative cooking time is... Less than the required stewing temperature after correction Then, allocate the time difference between the two to the remaining number of steps. This gives the remaining step cycle requirement for the material in the vessel from the current moment.

[0074] For example, the corrected stewing requirement for the first material group is 2892s. For a bottle of material that has just entered the stewing pot, its cumulative stewing time is 0 and the remaining number of steps is 240. Then the remaining step cycle requirement for this bottle of material in the pot is 2892÷240=12.05s.

[0075] For another bottle of material in the same material group that has already undergone 5 steps, if the actual step cycles for the 5 steps are 11.70s, 11.80s, 11.85s, 11.90s, and 11.95s respectively, then the cumulative cooking time is 59.20s, and the remaining number of steps is 235. The remaining cooking time to be completed is 2892 - 59.20 = 2832.80s, therefore the corresponding remaining step cycle requirement is approximately 12.05s.

[0076] The corrected stewing requirement for the other material group is 2969.4s. The cumulative stewing time of one bottle of material in the kettle is 600s, and the remaining number of steps is 190. Therefore, the remaining stewing time to be completed is 2369.4s, and the corresponding remaining step cycle requirement is approximately 12.47s.

[0077] The central controller calculates the remaining step cycle requirements for all materials in the reactor with a remaining step count greater than zero. For example, if the remaining step cycle requirements for each bottle of material in the reactor are 12.05s, 12.08s, 11.96s, 12.47s, 12.12s, and 12.20s, the largest one, 12.47s, is taken as the target step cycle.

[0078] Therefore, when a bottle of material in the reactor has experienced a short actual execution step cycle in the preceding process, its cumulative stewing time is relatively small, and the demand for subsequent remaining step cycles increases accordingly; when a bottle of material in the reactor has experienced a long actual execution step cycle, its cumulative stewing time is relatively large, and the demand for subsequent remaining step cycles decreases accordingly. Thus, the actual stewing time experienced by each bottle of material in the reactor is included in the subsequent step cycle determination process.

[0079] For step S33, the target stepping cycle is limited to between a preset minimum allowable stepping cycle and a preset maximum allowable stepping cycle. For example, based on the stroke of the stewing pot stepping mechanism, the tray positioning time, the inlet handover time, and the outlet ejection and reset time, the preset minimum allowable stepping cycle is set to 11.5s, and the preset maximum allowable stepping cycle is set to 13.5s. When the target stepping cycle is 12.47s, it falls between the preset minimum allowable stepping cycle and the preset maximum allowable stepping cycle; therefore, the corrected target stepping cycle is 12.47s.

[0080] When the target step cycle is less than 11.5s, the corrected target step cycle is set to 11.5s; when the target step cycle is greater than 13.5s, the corrected target step cycle is set to 13.5s. The corresponding materials that cause the remaining step cycle requirement to exceed 13.5s are recorded as boundary control materials for key review during export sampling inspection.

[0081] When the corrected target step cycle is different from the current execution step cycle, an intermediate step cycle is generated based on the current execution step cycle, the corrected target step cycle, and the preset transition step number.

[0082] For example, if the current execution step cycle is 11.90s, the corrected target step cycle is 12.47s, and the preset transition step number is 3, then three continuously changing intermediate step cycles of 12.09s, 12.28s, and 12.47s will be generated initially.

[0083] First, the intermediate stepping cycle corresponding to 12.09s is verified based on the acceleration and deceleration boundaries of the stepping mechanism in the stewing pot. When the acceleration and deceleration boundaries are met, 12.09s is written into the stepping trigger timer and executed. After execution, 12.09s is added to the cumulative stewing time of each bottle of material in the pot, the remaining stepping count of each bottle of material in the pot is decremented by 1, and the remaining stepping cycle requirement and target stepping cycle of all materials in the pot are recalculated based on the updated cumulative stewing time and remaining stepping count.

[0084] If the revised target step cycle is still 12.47s, then 12.28s will continue to be used as the next intermediate step cycle; if the revised target step cycle changes, then the already executed 12.09s will be used as the new current execution step cycle, and the subsequent intermediate step cycle will be re-determined based on the new current execution step cycle, the new revised target step cycle, and the preset transition steps.

[0085] Before writing the step trigger timer for each intermediate step cycle, the acceleration and deceleration boundaries of the stewing pot's stepping mechanism are checked. When the change in drive speed corresponding to an intermediate step cycle exceeds the allowable range, the intermediate step cycle is corrected by increasing the number of transition steps or decreasing the amount of change in a single step cycle.

[0086] For example, after the actual step execution corresponding to 12.09s is completed, the material in the pot with the aforementioned cumulative stewing time of 59.20s is updated to 71.29s, and the remaining number of steps changes from 235 to 234; the material in the pot with the aforementioned cumulative stewing time of 600s is updated to 612.09s, and the remaining number of steps changes from 190 to 189. Subsequently, the remaining step cycle requirement and target step cycle are re-determined based on the updated cumulative stewing time and remaining number of steps.

[0087] When the corrected target step cycle is the same as the currently executed step cycle, the corrected target step cycle is directly written into the step trigger timer. Regardless of whether an intermediate step cycle or the corrected target step cycle is executed, after each actual step is completed, the cumulative cooking time and remaining number of steps for each bottle of material in the reactor are updated according to the actual executed step cycle, and the next round of target step cycle calculation is performed.

[0088] When there is a short-term shortage of bottles at the inlet of the stewing pot, the previous valid current execution step cycle is maintained, and the cumulative stewing time and remaining step count of the existing materials in the pot are updated. After the materials are restored to the stewing pot, the target step cycle is re-determined based on the latest in-pot operation record of all materials in the pot.

[0089] S40: Adjust the target speed of the filling section according to the current number of bottles in the reordering buffer, and adjust the target speed of the cooling section according to the material release pulse interval at the outlet of the stewing kettle.

[0090] In this embodiment, step S40 includes: Step S41: Obtain the current number of bottles in the reordering buffer, and compare the current number of bottles in the reordering buffer with the preset lower limit number of bottles and the preset upper limit number of bottles respectively; when the current number of bottles in the reordering buffer is lower than the preset lower limit number of bottles, increase the target speed of the filling section by a preset speed step; when the current number of bottles in the reordering buffer is higher than the preset upper limit number of bottles, decrease the target speed of the filling section by a preset speed step; when the current number of bottles in the reordering buffer is greater than or equal to the preset lower limit number of bottles and less than or equal to the preset upper limit number of bottles, maintain the target speed of the filling section; after performing low-pass filtering and acceleration boundary verification on the target speed of the filling section, output it to the filling section conveyor controller. Step S42: Collect the material release pulse at the outlet of the stewing pot each time material is pushed out. Calculate the average release interval between the time intervals of material release pulses at the outlets of adjacent stewing pots within a preset sliding window. Divide the center distance between adjacent bottles in the cooling section by the average release interval to obtain the target speed of the cooling section. Perform low-pass filtering on the target speed of the cooling section and output it to the cooling section conveyor controller.

[0091] Specifically, this step uses different feedback quantities to adjust the speed for the filling section located upstream of the stewing pot and the cooling section located downstream of the stewing pot.

[0092] For step S41, the central controller reads the current number of bottles in the reordering buffer and compares it with the preset lower limit and the preset upper limit. When the current number of bottles in the reordering buffer is lower than the preset lower limit, the target speed of the filling section is increased by a preset speed step; when the current number of bottles in the reordering buffer is higher than the preset upper limit, the target speed of the filling section is decreased by a preset speed step; when the current number of bottles in the reordering buffer is greater than or equal to the preset lower limit and less than or equal to the preset upper limit, the target speed of the filling section is maintained.

[0093] For example, the reordering buffer has 24 buffer bottle positions, a preset lower limit of 8 bottles, a preset upper limit of 18 bottles, a preset speed step of 2 bottles / min, and a current filling segment target speed of 100 bottles / min. When the current number of bottles in the reordering buffer is 7, the target filling segment speed is increased from 100 bottles / min to 102 bottles / min; when the current number of bottles in the reordering buffer is 20, the target filling segment speed is decreased from 100 bottles / min to 98 bottles / min; and when the current number of bottles in the reordering buffer is 12, the speed is maintained at 100 bottles / min.

[0094] Each time a new target speed for the filling section is obtained, a low-pass filter is applied to the target speed, causing the output speed to gradually change from the actual speed of the previous control cycle to the new target speed. Further, it is determined whether the speed change per unit time exceeds the preset acceleration boundary of the corresponding conveying mechanism. If the speed change exceeds the preset acceleration boundary, the speed change is limited to within the preset acceleration boundary, and then the processed speed command is output to the filling section conveyor controller.

[0095] For step S42, each time material is discharged from the stewing pot, the outlet sensor generates a material release pulse at the outlet of the stewing pot. The central controller saves the occurrence time of each material release pulse at the outlet of the stewing pot within a preset sliding window, calculates the time interval between material release pulses at the outlets of adjacent stewing pots, and calculates the average value of each time interval to obtain the average release interval.

[0096] For example, if the material release pulses from the cooking vessel outlet in the last 10 times form 9 adjacent time intervals, and the sum of the 9 time intervals is 120.5s, then the average release interval is approximately 13.39s. If the center-to-center distance between adjacent bottles in the cooling section is 0.15m, then dividing the center-to-center distance between adjacent bottles in the cooling section by the average release interval yields a target velocity of approximately 0.0112m / s for the cooling section.

[0097] The target speed of the cooling section is low-pass filtered and then output to the cooling section conveyor controller. The cooling section conveyor controller adjusts the conveyor belt speed according to the target speed of the cooling section, so that the material conveying cycle of the cooling section matches the actual release cycle of the stewing kettle.

[0098] When the material release pulse at the outlet of the stewing kettle is briefly missing, maintain the target speed of the previous effective cooling section and record the abnormal state of the outlet pulse; when the current number of bottles in the reordering buffer changes rapidly in a short period of time, limit the single change in the target speed of the filling section; when the production line generates an emergency stop signal, freeze the current speed command and resume speed matching control after the emergency stop is lifted.

[0099] S50: Update the correction coefficient bound to the newly created material group based on the sampling results of the material after stewing.

[0100] In this embodiment, step S50 includes: Step S51: Collect images of the stewed material at preset sampling intervals, extract the outlet area ratio and outlet sedimentation fluctuation parameters, and compare the outlet area ratio and outlet sedimentation fluctuation parameters with the corresponding preset target intervals. Step S52: When at least one of the export area ratio and export settlement fluctuation parameters is lower than the corresponding preset target range lower limit for a consecutive preset number of times, the correction coefficient is increased; when neither the export area ratio nor the export settlement fluctuation parameter is lower than the corresponding preset target range lower limit, and at least one parameter is higher than the corresponding preset target range upper limit for a consecutive preset number of times, the correction coefficient is decreased; when the conditions for increasing or decreasing the correction coefficient are not met, the correction coefficient is maintained. Step S53: When increasing or decreasing the correction coefficient, determine the correction step size based on the deviation of the outlet area ratio and the outlet settlement fluctuation parameter from the corresponding preset target range, apply a preset upper limit constraint to the correction step size, increase or decrease the correction coefficient according to the correction step size, and bind the updated correction coefficient to the subsequently newly created material group.

[0101] Specifically, the outlet sampling inspection component is located at the outlet of the stewing kettle or at the front end of the cooling section, and includes a light source, an industrial camera, a positioning trigger sensor, and an image processing unit. Images of the stewed material are collected at preset sampling intervals, for example, once every 20 bottles, or a preset number of bottles are sampled after the materials corresponding to each material group arrive at the outlet.

[0102] For step S51, the bottle area is located and the solids area is segmented in the image of the material after stewing to obtain the projected area of ​​the solids after stewing. The ratio of the projected area of ​​the solids after stewing to the effective observation area of ​​the bottle is calculated, or the ratio of the projected area of ​​the solids after stewing to the initial projected area of ​​the solids in the corresponding bottle material at the filling station is calculated to obtain the outlet area ratio. The same outlet area ratio calculation method is used in the same production process.

[0103] Multiple frames of images were continuously acquired during the short-term settling period of the material after stewing. The outlet settlement fluctuation parameter was determined based on at least one of the following: changes in the center of gravity of the solids, changes in the area of ​​the solids at different heights, or changes in the position of the solids boundary. The same method for determining the outlet settlement fluctuation parameter was used for the same production line during the establishment of the preset target range and online sampling inspection.

[0104] For step S52, when at least one of the outlet area ratio and outlet settlement fluctuation parameters is lower than the corresponding lower limit of the preset target range for a consecutive preset number of times, the correction coefficient is increased. When neither the outlet area ratio nor the outlet settlement fluctuation parameter is lower than the corresponding lower limit of the preset target range, and at least one parameter is higher than the corresponding upper limit of the preset target range for a consecutive preset number of times, the correction coefficient is decreased. When the conditions for increasing or decreasing the correction coefficient are not met, the current correction coefficient is maintained, thereby covering short-term deviations that have not yet reached the consecutive preset number of times.

[0105] For step S53, after satisfying the conditions for increasing or decreasing the correction coefficient, the deviations of the outlet area ratio and outlet settlement fluctuation parameters relative to the corresponding preset target interval boundaries are calculated, and the deviation magnitude is determined based on the deviations in continuous sampling. A larger correction step size is used when the deviation magnitude increases, and a smaller correction step size is used when the deviation magnitude decreases, and the correction step size is limited to within the preset maximum allowable correction step size.

[0106] For example, if the target value for the export area ratio is set to 4.00, with an allowable deviation of 0.15, then the corresponding preset target range is 3.85 to 4.15. The export sampling interval is once every 20 bottles. The export area ratios obtained from the most recent 5 samplings are 3.82, 3.79, 3.81, 3.80, and 3.83, respectively. All 5 results are lower than the lower limit of the preset target range of 3.85, thus meeting the condition for adding a correction coefficient.

[0107] The deviations of the export area ratios from the preset target range lower limit of 3.85 in the above five instances were 0.03, 0.06, 0.04, 0.05, and 0.02, respectively, with an average deviation of 0.04. Based on the pre-established correspondence between deviation magnitude and correction step size, the correction step size was determined to be 0.01 when the deviation magnitude was 0.04. If the preset maximum allowable correction step size is 0.02, then 0.01 does not exceed the preset maximum allowable correction step size; therefore, the current correction coefficient was increased from 1.00 to 1.01.

[0108] The updated correction factor does not change the correction factor bound to the historical material group that has already been established, but is bound to the newly created material group.

[0109] For example, if the maximum stewing time requirement index for a subsequent newly created material group is 48.2 min, and the updated correction coefficient is 1.01, then the corresponding corrected stewing requirement is 48.682 min, or 2920.92 s. When the first bottle of material in this subsequent newly created material group enters the stewing pot corresponding to 240 steps of the complete stewing path, the cumulative stewing time of the bottle in the pot is 0, and the remaining number of steps is 240. According to the calculation method of the remaining step cycle requirement in step S30, the remaining step cycle requirement of the bottle in the pot is approximately 12.17 s.

[0110] If the maximum remaining step cycle requirement of other materials in the reactor is 12.08s, then 12.17s is taken as the current target step cycle; if there are other materials in the reactor with a remaining step cycle requirement of 12.30s, then 12.30s is taken as the current target step cycle.

[0111] Therefore, the sampling results of the materials after stewing are adjusted by modifying the correction coefficient bound to the newly created material group to change the corresponding corrected stewing requirements. Furthermore, the cumulative stewing time and remaining number of steps of each bottle in the pot are used to determine the subsequent target step cycle, while the correction coefficient bound to the established historical material group remains unchanged.

[0112] The specific operation process will be explained in detail. A certain fresh stewed bird's nest production line includes a 12-head filling and capping machine, a rigid section conveyor belt, a 24-bottle reordering buffer zone, a stepping stewing pot with 240 steps corresponding to the complete stewing path, a flexible section conveyor belt, a cooling tunnel, an edge computing node IPC1, a central controller IPC2, a dynamic weighing unit, a backlight image acquisition unit, and an outlet image acquisition unit.

[0113] After the weight data and backlight projection image data of a single bottle of material are collected at the filling station, the weight response time parameter, sedimentation competition parameter, total mass of material after filling, solid projection area change parameter, expansion stabilization time parameter and static observation end area ratio are obtained according to step S10, and the corresponding stewing time requirement index is obtained based on the preset mapping table.

[0114] After a single bottle of material enters the reordering buffer, the cooking time requirement index difference between each bottle of material and the previous material entering the stewing pot is compared according to step S20. The material with the smallest difference is given priority to be sent into the stewing pot. When there are multiple materials with the smallest difference, the material to be entered is determined by the waiting time, and the temporary avoidance and backfilling of the blocking material is completed by the temporary storage bottle position.

[0115] After the materials enter the stewing pot, the material group boundary is determined according to the preset group size and preset demand mutation threshold in step S30. The current effective correction coefficient is bound to the newly created material group. The corrected stewing demand is determined based on the maximum stewing time demand index and correction coefficient of the material group, and the cumulative stewing time and remaining steps of each bottle of material in the pot are continuously maintained. The central controller determines the remaining step cycle demand of each bottle of material in the pot and takes the maximum remaining step cycle demand as the target step cycle. After each actual step is completed, the in-pot operation record is updated according to the actual executed step cycle, and the target step cycle is redefined.

[0116] At the same time, according to step S40, the target speed of the filling section is adjusted based on the current number of bottles in the reordering buffer, and the target speed of the cooling section is adjusted based on the material release pulse interval at the outlet of the stewing kettle, so that the upstream material supply and downstream material conveying of the stewing kettle are matched with the corresponding local operating states.

[0117] After stewing, the materials are subjected to outlet sampling inspection according to step S50. When the outlet area ratio or outlet settlement fluctuation parameter meets the preset continuous deviation condition, the correction step size is determined according to the deviation range and the correction coefficient is updated. The updated correction coefficient is bound to the subsequently newly created material group, and then step S30 converts the updated and corrected stewing requirements into the actual target step cycle.

[0118] This forms a speed matching control process for the fresh stewed bird's nest production line, which consists of filling station detection, determination of stewing time requirement index, finite reordering, material group division, rolling calculation of remaining step cycle requirement of material in the pot, speed adjustment of filling section, speed adjustment of cooling section, and material feedback correction after stewing.

[0119] The second embodiment of the present invention proposes a speed matching control system for a fresh stewed bird's nest production line, including a parameter acquisition and index calculation module, a reordering module, a stepping cycle control module, a speed matching control module, and a feedback correction module.

[0120] The parameter acquisition and index calculation module is used to collect the weight data and backlight projection image data of a single bottle of material at the filling station, extract the weight response features and solid projection features to form a parameter set, and interpolate the stewing time requirement index based on the preset mapping table. The reordering module is used in the reordering buffer zone after filling and capping and before the stewing inlet. It compares the difference in stewing time requirement index between each bottle of material and the material that entered the stewing pot the previous time, and sends the material with the smallest difference into the stewing pot. The step cycle control module is used to divide the materials continuously entering the stewing pot into material groups according to the preset group size and preset demand mutation threshold, and bind correction coefficients. Based on the maximum stewing time demand index and correction coefficient of each material group, the corrected stewing demand is determined. The remaining step cycle demand is determined by combining the cumulative stewing time of each bottle in the pot and the remaining number of steps. The maximum value of the remaining step cycle demand of each bottle in the pot is taken as the target step cycle. After being corrected by the preset step cycle upper and lower limits, it is written into the step trigger timer. The speed matching control module is used to adjust the target speed of the filling section according to the current number of bottles in the reordering buffer, and to adjust the target speed of the cooling section according to the pulse interval of material release at the outlet of the stewing kettle. The feedback correction module is used to update the correction coefficients bound to newly created material groups based on the results of material sampling inspections after stewing.

[0121] The parameter acquisition and index calculation module corresponds to step S10 in the first embodiment. This module connects the dynamic weighing unit and the backlight image acquisition unit, receives weight data and backlight projection image data corresponding to the same single bottle of material, and performs weight data filtering, weight response feature extraction, solid projection area extraction, and parameter set formation. Following the method described in step S13 of the first embodiment, the module searches for neighboring records in a preset mapping table and performs weighted interpolation based on normalized distance to obtain the stewing time requirement index for the corresponding single bottle of material. When the collected data does not meet the preset complete collection conditions, an alternative stewing time requirement index is determined according to step S14 of the first embodiment.

[0122] The reordering module corresponds to step S20 in the first embodiment. The reordering module includes a reordering buffer for accommodating materials and is connected to a conveying mechanism, a bottle-dispensing mechanism, a temporary bottle position, and an outlet positioning sensor within the reordering buffer. The reordering module reads the stewing time requirement index and waiting time of each bottle of material, uses the stewing time requirement index of the previous material entering the stewing pot as a comparison benchmark to determine the material to be entered, and when there is obstructing material between the material to be entered and the outlet position of the reordering buffer, it completes the temporary avoidance of obstructing material, the output of the material to be entered, and the backfilling of obstructing material according to the temporary avoidance sequence described in the first embodiment.

[0123] The step cycle control module corresponds to step S30 in the first embodiment. The step cycle control module obtains the stewing time requirement index corresponding to the material entering the stewing pot, determines the material group boundary based on the preset group size and preset requirement mutation threshold, binds the currently effective correction coefficient to the newly created material group, and maintains the in-pot operation record corresponding to the material in each bottle. The step cycle control module determines the corrected stewing requirement based on the maximum stewing time requirement index and correction coefficient of each material group, determines the remaining step cycle requirement based on the cumulative stewing time, remaining step count, and corrected stewing requirement of the corresponding material group for each bottle in the pot, takes the maximum remaining step cycle requirement as the target step cycle, and generates the actual step cycle written to the step trigger timer according to the preset minimum allowable step cycle, preset maximum allowable step cycle, and drive acceleration / deceleration boundary. After each actual step is completed, the step cycle control module updates the cumulative stewing time and remaining step count of each bottle in the pot and redetermines the target step cycle.

[0124] The speed matching control module corresponds to step S40 in the first embodiment. The speed matching control module acquires the current number of bottles in the reordering buffer and adjusts the target speed of the filling section based on the comparison results between the current number of bottles in the reordering buffer and the preset lower limit number of bottles and the preset upper limit number of bottles. Simultaneously, it acquires the material release pulses at the outlet of the stewing kettle, determines the target speed of the cooling section based on the average release interval between material release pulses at the outlets of adjacent stewing kettles within a preset sliding window and the center distance between adjacent bottle positions in the cooling section, and outputs corresponding speed control commands to the filling section transmission controller and the cooling section transmission controller, respectively.

[0125] The feedback correction module corresponds to step S50 in the first embodiment. The feedback correction module acquires an image of the material after stewing, extracts the outlet area ratio and outlet settling fluctuation parameters from the image, and compares them with the corresponding preset target intervals. When the conditions for increasing or decreasing the correction coefficient are met, the correction step size is determined based on the deviation from the preset target interval. A preset upper limit constraint is applied to the correction step size, and the correction coefficient is updated. The updated correction coefficient is then bound to the subsequently created material group. When the conditions for increasing or decreasing the correction coefficient are not met, the correction coefficient is maintained.

[0126] In one implementation structure, the parameter acquisition and index calculation module, reordering module, step cycle control module, speed matching control module, and feedback correction module are executed by one or more processors from an industrial computer, PLC, or edge computing node. Data transmission between modules occurs via industrial Ethernet, fieldbus, or digital trigger signals. Bottle identification for individual materials is obtained through visual coding, electronic tags, encoder counting, or production station sequence mapping, ensuring that weight data, backlit projection image data, stewing time requirement index, buffer bottle position information, in-boiler operation records, and post-stewing material sampling results are correlated with the corresponding individual bottle material.

[0127] It should be noted that the above embodiments illustrate the present invention by dividing it into steps and functional modules. In practical applications, the data processing and control functions corresponding to each step can be centrally or distributed according to the hardware configuration of the controller, and each functional module can be executed by the same processor or by different processors respectively. The division of steps and functional modules is used to illustrate the technical processing relationship of the present invention and does not constitute a limitation on the specific hardware deployment method.

[0128] The terms “first”, “second”, etc., are used to distinguish similar objects, not to describe or indicate a specific order or sequence.

[0129] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent in such process, method, article, or apparatus / device.

[0130] The technical solution of the present invention has been described in conjunction with specific embodiments. Those skilled in the art can make equivalent changes or substitutions to the relevant technical features without departing from the technical concept of the present invention.

Claims

1. A speed matching control method for a fresh-stewed bird's nest production line, characterized in that, include: Weight data and backlight projection image data of a single bottle of material are collected at the filling station. Weight response features and solid projection features are extracted to form a parameter set. The stewing time requirement index is obtained by interpolation based on a preset mapping table. In the reordering buffer zone after filling and capping and before the stewing inlet, the difference in stewing time requirement index between each bottle of material and the previous material entering the stewing pot is compared, and the material with the smallest difference is sent into the stewing pot. The materials continuously entering the stewing pot are divided into material groups according to the preset group size and preset demand mutation threshold, and a correction coefficient is bound. The corrected stewing demand is determined based on the maximum stewing time demand index and correction coefficient of each material group. The remaining step cycle demand is determined by combining the cumulative stewing time of each bottle in the pot and the remaining number of steps. The maximum value of the remaining step cycle demand of each bottle in the pot is taken as the target step cycle. After being corrected by the preset step cycle upper and lower limits, it is written into the step trigger timer. Adjust the target speed of the filling section according to the current number of bottles in the reordering buffer, and adjust the target speed of the cooling section according to the pulse interval of material release at the outlet of the stewing kettle; The correction coefficients bound to newly created material groups are updated based on the results of material sampling inspections after stewing.

2. The method according to claim 1, characterized in that, Weight response features and solid projection features are extracted to form a parameter set. Based on a preset mapping table, the stewing time requirement index is obtained, including: Obtain the empty bottle tare weight, filter the weight data and determine the baseline weight fluctuation range, weight change rate, static observation fluctuation energy and end weight. Determine the weight response start time based on the baseline weight fluctuation range, determine the weight change peak time based on the weight change rate, determine the weight response time parameter based on the weight response start time and weight change peak time, determine the sedimentation competition parameter based on the static observation fluctuation energy, and determine the total mass of material after filling based on the end weight and empty bottle tare weight. The solid object projection is separated frame by frame from the backlight projection image data to obtain the solid object projection area and the vertical distribution dispersion. The solid object projection area change parameters and the area ratio of the last static observation segment are determined based on the temporal change of the solid object projection area. The stretching stabilization time parameters are determined based on the solid object projection area change parameters and the vertical distribution dispersion. The parameters are: weight response time, sedimentation competition, total mass of material after filling, change in projected area of ​​solids, expansion stabilization time, and area ratio of the final static observation segment. The nearest neighbor record with the normalized distance to the parameter set is found in the preset mapping table. The stewing time requirement index corresponding to the nearest neighbor record is weighted and interpolated according to the normalized distance between each neighbor record and the parameter set to obtain the stewing time requirement index of the current bottle material.

3. The method according to claim 1, characterized in that, Also includes: When the weight data or backlight projection image data does not meet the preset complete acquisition conditions, the corresponding single bottle material is identified as an abnormal acquisition bottle. The most recently preset number of successfully output stewing time requirement indices are read, the median of the read stewing time requirement indices is calculated, and the alternative stewing time requirement index for the abnormal acquisition bottle is obtained. The alternative stewing time requirement index is used as the stewing time requirement index for the abnormal acquisition bottle for material selection in the reordering buffer.

4. The method according to claim 1, characterized in that, Compare the cooking time requirement index difference between each bottle of material and the material that previously entered the stewing pot, and send the material with the smallest difference into the stewing pot, including: Read the waiting time and stewing time requirement index of each bottle of material in the reordering buffer, calculate the difference in stewing time requirement index between each bottle of material and the previous material entering the stewing pot, determine the material with the smallest difference as the material to be entered, and when there are multiple materials with the smallest difference, determine the material with the largest waiting time as the material to be entered. When there are obstructing materials between the material to be introduced and the outlet of the reordering buffer, the temporary avoidance order is determined according to the difference in stewing time requirement index between each obstructing material and the material to be introduced. The obstructing materials are moved into the temporary storage bottle according to the temporary avoidance order. After the material to be introduced is sent into the stewing pot, the obstructing materials are then backfilled into the empty buffer bottle.

5. The method according to claim 1, characterized in that, The materials continuously entering the stewing pot are divided into material groups according to preset group size and preset demand mutation threshold, and a correction coefficient is attached. The target step cycle is determined by: The preset initial correction factor is used as the initial current effective correction factor, and the current effective correction factor is replaced by the correction factor updated based on the sampling results of the materials after stewing. The material group boundary is determined by comparing the difference in stewing time requirement index between the material currently entering the stewing pot and the material previously entering the stewing pot with the preset requirement mutation threshold, and by comparing the number of bottles to be divided into material groups with the preset group size. The current effective correction coefficient is then bound to the newly created material group. Update the maximum stewing time requirement index of the material group to which the material belongs in the pot, and determine the corrected stewing requirement of the corresponding material group by multiplying the maximum stewing time requirement index with the correction coefficient bound to the corresponding material group. For each bottle of material in the autoclave with a remaining number of steps greater than zero, the difference between the corrected stewing requirement of the corresponding material group and the corresponding cumulative stewing time is limited to not less than zero. The limited difference is divided by the corresponding remaining number of steps to obtain the remaining step cycle requirement of each bottle of material in the autoclave, and the maximum value of the remaining step cycle requirement of each bottle of material in the autoclave is selected as the target step cycle.

6. The method according to claim 5, characterized in that, The steps to be written to the step trigger timer after being corrected by the preset step period upper and lower limits include: The target step cycle is restricted to between the preset minimum allowable step cycle and the preset maximum allowable step cycle to obtain the corrected target step cycle; When the corrected target step cycle is different from the current execution step cycle, the intermediate step cycle is determined based on the current execution step cycle, the corrected target step cycle, and the preset transition step number. The intermediate step cycle is corrected according to the acceleration and deceleration boundary of the stewing pot stepping mechanism and then written into the step trigger timer. When the corrected target step cycle is the same as the current execution step cycle, the corrected target step cycle is written into the step trigger timer. After each actual step is completed, the actual step cycle is added to the cumulative cooking time of each bottle of material in the reactor, the remaining number of steps for each bottle of material in the reactor is reduced by one, and the remaining step cycle requirement and target step cycle for each bottle of material in the reactor are re-determined.

7. The method according to claim 1, characterized in that, Adjusting the target filling speed based on the current number of bottles in the reordering buffer includes: Get the current number of bottles in the reordering buffer, and compare the current number of bottles in the reordering buffer with the preset lower limit number of bottles and the preset upper limit number of bottles respectively; When the current number of bottles in the reordering buffer is lower than the preset lower limit, the target speed of the filling section is increased by a preset speed step; when the current number of bottles in the reordering buffer is higher than the preset upper limit, the target speed of the filling section is decreased by a preset speed step; when the current number of bottles in the reordering buffer is greater than or equal to the preset lower limit and less than or equal to the preset upper limit, the target speed of the filling section is maintained. After performing low-pass filtering and acceleration boundary verification on the target speed of the filling section, the output is sent to the filling section conveyor controller.

8. The method according to claim 1, characterized in that, Adjusting the target speed of the cooling section based on the pulse interval of material release from the stewing kettle outlet includes: Each time material is ejected from the stewing pot, the material release pulse at the outlet of the stewing pot is collected, and the average release interval is calculated for the time interval between adjacent material release pulses at the outlet of the stewing pot within a preset sliding window. The target speed of the cooling section is obtained by dividing the center distance between adjacent bottle positions in the cooling section by the average release interval. The target speed of the cooling section is then low-pass filtered and output to the cooling section conveyor controller.

9. The method according to claim 1, characterized in that, The correction factors for newly created material groups are updated based on the results of material sampling after stewing, including: Images of the stewed material were collected at preset sampling intervals, and the outlet area ratio and outlet sedimentation fluctuation parameters were extracted. The outlet area ratio and outlet sedimentation fluctuation parameters were then compared with the corresponding preset target intervals. When at least one of the export area ratio and export settlement fluctuation parameters is lower than the lower limit of the corresponding preset target range for a consecutive preset number of times, the correction coefficient is increased; when neither the export area ratio nor the export settlement fluctuation parameter is lower than the lower limit of the corresponding preset target range, and at least one parameter is higher than the upper limit of the corresponding preset target range for a consecutive preset number of times, the correction coefficient is decreased; when the conditions for increasing or decreasing the correction coefficient are not met, the correction coefficient is maintained. When increasing or decreasing the correction coefficient, the correction step size is determined based on the deviation of the export area ratio and the export settlement fluctuation parameter from the corresponding preset target range. A preset upper limit constraint is applied to the correction step size, and the correction coefficient is increased or decreased according to the correction step size. Bind the updated correction factor to the newly created material group.

10. A speed matching control system for a fresh-stewed bird's nest production line, characterized in that, include: The parameter acquisition and index calculation module is used to collect the weight data and backlight projection image data of a single bottle of material at the filling station, extract the weight response features and solid projection features to form a parameter set, and interpolate the stewing time requirement index based on the preset mapping table. The reordering module is used in the reordering buffer zone after filling and capping and before the stewing inlet. It compares the difference in stewing time requirement index between each bottle of material and the material that entered the stewing pot the previous time, and sends the material with the smallest difference into the stewing pot. The step cycle control module is used to divide the materials continuously entering the stewing pot into material groups according to the preset group size and preset demand mutation threshold, and bind correction coefficients. Based on the maximum stewing time demand index and correction coefficient of each material group, the corrected stewing demand is determined. The remaining step cycle demand is determined by combining the cumulative stewing time of each bottle in the pot and the remaining number of steps. The maximum value of the remaining step cycle demand of each bottle in the pot is taken as the target step cycle. After being corrected by the preset step cycle upper and lower limits, it is written into the step trigger timer. The speed matching control module is used to adjust the target speed of the filling section according to the current number of bottles in the reordering buffer, and to adjust the target speed of the cooling section according to the pulse interval of material release at the outlet of the stewing kettle. The feedback correction module is used to update the correction coefficients bound to newly created material groups based on the results of material sampling inspections after stewing.

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