A method and system for controlling the process of forming a large bolus

Abstract

This application provides a method and system for controlling the forming process of large honey pills, applied in the field of large honey pill processing technology. By calculating the apparent viscosity index of the current batch of material and combining it with speed comparison, the method identifies speed mismatch in the initial stage of batch change. Based on this, the initial feed speed of the forming mechanism is recalculated according to the actual moving speed. The forming mechanism is only activated after the material accumulation in the transition area reaches a preset condition, physically eliminating the risk of forced stretching of the material. After activation, the speeds of both are adjusted collaboratively based on the actual output state of the material conveying mechanism until the target production cycle is reached. Therefore, this application effectively solves the problem of speed matching failure caused by material changes during batch change production, which leads to underweight pills and irregular pill shapes. It ensures the accuracy of pill weight and the integrity of pill shape in the initial stage of batch change, significantly reducing scrap rate and manual adjustment costs.

Description

Technical Field

[0001] This application relates to the field of large honey pill processing technology, and in particular to a method and system for controlling the forming process of large honey pills. Background Technology

[0002] Large honey pill machines are specialized equipment used for the production of traditional Chinese medicine honey pills, primarily serving small pharmaceutical factories, hospital preparation rooms, traditional Chinese medicine research institutions, and pharmacies. Therefore, their production process typically involves frequent batch changes for multiple varieties and small batches.

[0003] In the daily production operation of the large honey pellet machine, the equipment usually operates the extrusion strip forming mechanism (i.e., material conveying mechanism) and the pellet rolling mechanism (forming mechanism) based on preset parameters to maintain the matching of extrusion speed and pellet rolling feed speed.

[0004] However, in batch changeover processes under a multi-variety, small-batch production model, existing control logic mainly relies on historical parameters or manual experience. When the new batch formula results in a material viscoelasticity significantly higher than the previous batch, the internal shear resistance and frictional resistance of the material increase, causing the actual extrusion line speed to be significantly lower than the preset value. At this time, the shot rubbing mechanism still operates at the original set speed, resulting in a mismatch between shot rubbing demand and extrusion supply.

[0005] The pellet rolling roller, due to its high linear speed, drags the insufficient supply of pellets, resulting in thinner pellets, lighter pellet weight, irregular shape, and trailing marks. This lack of adaptability to predict changes in the viscoelasticity of new batches of materials leads to low pass rates in the initial batch transition period. Frequent trial adjustments cause serious material waste and equipment idling, severely restricting production efficiency and product quality stability.

[0006] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0007] In view of the shortcomings of the prior art, this application provides a method and system for controlling the forming process of large honey pills, which aims to solve the problem of mismatch between the running speed of the material conveying mechanism and the running speed of the forming mechanism caused by the change in viscoelasticity of the new batch of materials in multi-variety batch production, which leads to the problem of pills being underweight and irregular in shape.

[0008] In a first aspect, a method for controlling the forming process of large honey pills is applied to a large honey pill machine, wherein the large honey pill machine includes at least a material conveying mechanism and a forming mechanism, and the method includes the following steps:

[0009] S1: During the production batch changeover start-up phase, the material conveying mechanism is driven to operate according to preset parameters within the trial operation period, and the actual moving speed of the material is obtained;

[0010] S2: Calculate the apparent viscosity index of the current batch of material based on the driving torque of the material conveying mechanism, the material pressure at the output end, and the actual moving speed.

[0011] S3: Based on the actual moving speed and the apparent viscosity index, determine whether there is a speed mismatch caused by changes in the viscoelasticity of the material;

[0012] S4: When the speed mismatch exists, calculate the initial feed speed of the forming mechanism based on the actual moving speed;

[0013] S5: Monitor the material accumulation level in the transition area between the material conveying mechanism and the forming mechanism. When the material accumulation level reaches the preset condition, drive the forming mechanism to start running according to the initial feed speed.

[0014] S6: After the forming mechanism is started, the actual moving speed and the initial feed speed are adjusted in coordination based on the actual moving speed until the target production cycle is reached.

[0015] Furthermore, step S6 includes:

[0016] S61: After the forming mechanism is started, the actual moving speed is gradually increased according to the preset stabilization time, based on the actual moving speed, to obtain a new actual moving speed;

[0017] S62: Within a preset stabilization time, monitor whether the driving torque of the material conveying mechanism and the material pressure at the output end are both within the corresponding safety threshold.

[0018] S63: If all are within the corresponding safety threshold, then calculate the updated feed speed of the forming mechanism based on the new actual moving speed;

[0019] S64: Repeat steps S61 to S63 until the new actual moving speed and the updated feed speed together reach the target production cycle time; wherein, the target production cycle time is the target production speed required by the process.

[0020] Furthermore, step S62 includes the following:

[0021] S621: If either the driving torque or the material pressure exceeds the corresponding safety threshold, the actual moving speed of the material conveying mechanism is reduced to a preset safety speed, and the feeding speed of the forming mechanism is reduced simultaneously; the preset safety speed is half of the current actual moving speed.

[0022] S622: If the driving torque and the material pressure are both within the corresponding safety threshold when running at a preset safe speed, then the preset safe speed is increased back to the actual moving speed before the deceleration.

[0023] S623: If the number of consecutive speed reduction operations reaches the warning count and the driving torque or the material pressure still exceeds its respective safety threshold, a shutdown alarm will be triggered.

[0024] Furthermore, step S64 includes:

[0025] S65: After reaching the target production cycle, the continuous forming stage is entered, and the material sag arc value of the transition area is collected in real time during the continuous forming stage.

[0026] S66: Calculate the length deviation between the material's sag arc value and the target arc reference value;

[0027] S67: Calculate the feed speed fine-tuning amount based on the length deviation using the proportional-integral-differential algorithm, and add the feed speed fine-tuning amount to the current feed speed of the forming mechanism to obtain the real-time feed speed;

[0028] S68: Drive the forming mechanism to operate at the real-time feed speed.

[0029] Furthermore, in step S67, calculating the feed rate fine-tuning amount based on the length deviation using a proportional-integral-differential algorithm includes the following steps:

[0030] S671: Perform time integration and time differentiation calculations on the length deviation to obtain the cumulative amount of length deviation and the rate of change of length deviation respectively;

[0031] S672: Multiply the length deviation, the cumulative length deviation, and the cumulative length deviation by the corresponding proportional coefficient, integral coefficient, and differential coefficient respectively, and then sum them to obtain the feed rate fine adjustment amount.

[0032] Furthermore, in step S2, the apparent viscosity index is calculated as follows: Apparent viscosity index = (driving torque * material pressure) / actual moving speed.

[0033] Furthermore, step S3 includes:

[0034] S31: Obtain the apparent viscosity index of the previous batch of material as the baseline viscosity index;

[0035] S32: Compare the actual moving speed with the preset molding feed speed, and compare the apparent viscosity index with the reference viscosity index, wherein the preset molding feed speed is the target feed speed required by the process.

[0036] S33: If the actual moving speed is less than the preset forming feed speed and the apparent viscosity index is greater than the reference viscosity index, it is determined that there is a speed mismatch caused by changes in the viscoelasticity of the material.

[0037] S34: If the actual moving speed is greater than or equal to the preset forming feed speed, or the apparent viscosity index is less than or equal to the reference viscosity index, then it is determined that there is no speed mismatch caused by changes in the viscoelasticity of the material.

[0038] S35: When there is no speed mismatch, the preset forming feed speed is used as the initial feed speed.

[0039] Furthermore, step S4 includes:

[0040] S41: Calculate the difference between the apparent viscosity index and the reference viscosity index, and calculate the ratio of the difference to the apparent viscosity index to obtain the safety factor;

[0041] S42: Multiply the safety factor by the actual moving speed to obtain the initial feed speed of the forming mechanism.

[0042] Furthermore, step S5 includes:

[0043] S51: Real-time monitoring of the lowest point of the material's sag arc within the transition area;

[0044] S52: Calculate the current depth value of the material's sag arc based on the lowest point position;

[0045] S53: Compare the current depth value with a preset minimum safety buffer depth threshold;

[0046] S54: When the current depth value is greater than or equal to the minimum safety buffer depth threshold, it is determined that the material accumulation degree has reached the preset condition, and the forming mechanism is driven to start running according to the initial feed speed.

[0047] Secondly, a control system for the forming process of large honey pills, characterized in that, for implementing the steps of any of the above-described methods, the system comprises:

[0048] Acquisition module: During the production batch changeover start-up phase, the material conveying mechanism is driven to operate according to preset parameters within the trial operation time, and the actual moving speed of the material is acquired;

[0049] First calculation module: Calculates the apparent viscosity index of the current batch of material based on the driving torque of the material conveying mechanism, the material pressure at the output end, and the actual moving speed;

[0050] Judgment module: Based on the actual moving speed and the apparent viscosity index, determine whether there is a speed mismatch caused by changes in the viscoelasticity of the material;

[0051] Second calculation module: When the speed mismatch exists, calculate the initial feed speed of the forming mechanism based on the actual moving speed;

[0052] Drive module: Monitors the material accumulation level in the transition area between the material conveying mechanism and the forming mechanism. When the material accumulation level reaches a preset condition, it drives the forming mechanism to start running at the initial feed speed.

[0053] Adjustment module: After the forming mechanism is started, the actual moving speed is adjusted in conjunction with the initial feed speed based on the actual moving speed until the target production cycle is reached.

[0054] Beneficial Effects: The method and system for controlling the forming process of large honey pills proposed in this application can accurately identify speed mismatch caused by changes in the viscoelasticity of materials in the early stage of batch change by calculating the apparent viscosity index of the current batch of materials online and combining it with speed comparison. Based on this, the initial feed speed of the forming mechanism is recalculated according to the actual moving speed, and the forming mechanism is only started after the material accumulation degree in the transition area reaches the preset condition, thus physically eliminating the risk of forced stretching of materials. After starting, the speeds of the material conveying mechanism are adjusted in coordination with the actual output state of the material conveying mechanism until the target production cycle is reached. Thus, this application effectively solves the problem of speed matching failure caused by changes in material characteristics in batch production, which leads to underweight pills and irregular pill shapes, ensuring the accuracy of pill weight and integrity of pill shape in the early stage of batch change, and has the beneficial effect of significantly reducing scrap rate and manual adjustment costs. Attached Figure Description

[0055] Figure 1 This is a flowchart of a method for controlling the forming process of large honey pills proposed in this application.

[0056] Figure 2 This is a structural diagram of a control system for the forming process of large honey pills proposed in this application.

[0057] Labeling Explanation: 201, Acquisition Module; 202, First Calculation Module; 203, Judgment Module; 204, Second Calculation Module; 205, Driver Module; 206, Adjustment Module. Detailed Implementation

[0058] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. The components of the embodiments of this application described and marked in the accompanying drawings can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0059] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, terms such as "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0060] In the daily production operation of large honey pill making machines, the equipment typically operates the material conveying mechanism (e.g., extrusion strip making mechanism) and the forming mechanism (e.g., pill rolling mechanism) according to preset parameters to maintain the matching of extrusion speed and forming feed speed, ensuring that the material strip is fed into the forming area with a stable cross section. However, when changing batches in a multi-variety, small-batch production mode, when the proportion of hygroscopic medicinal powder in the new batch formula increases or the degree of honey refining is slightly adjusted, the overall viscoelasticity of the material is often significantly higher than that of the previous batch.

[0061] At this point, the frictional resistance between the material and the barrel wall and screw, as well as the internal shear resistance, increase significantly during the extrusion stage. Under the original drive parameters, the actual extrusion linear speed will be significantly lower than the preset value. If the control logic directly uses the parameters of the previous batch or relies on experience to set them at the beginning of the batch change, it lacks the ability to adapt to and predict the viscoelastic changes of the new batch of material. The actual extrusion speed will be significantly lower than the preset forming feed speed, resulting in a negative deviation between the two.

[0062] The forming mechanism then drags the insufficient supply of material strips at a high linear speed, causing the material strips to become thinner. This not only results in insufficient compression during forming but also reduces the clamping stability of the forming mechanism for thinner material strips. Ultimately, a large number of substandard products with light weight and irregular shape will appear in the initial stage of production, causing material waste and equipment idle time.

[0063] To solve the above problem, please refer to Figure 1 This application proposes a method for controlling the forming process of large honey pills, applied to a large honey pill machine. The large honey pill machine includes at least a material conveying mechanism and a forming mechanism. The method includes the following steps:

[0064] S1: During the production batch changeover start-up phase, drive the material conveying mechanism to run according to preset parameters within the trial operation time and obtain the actual moving speed of the material;

[0065] S2: Calculate the apparent viscosity index of the current batch of material based on the driving torque of the material conveying mechanism, the material pressure at the output end, and the actual moving speed.

[0066] S3: Based on the actual moving speed and apparent viscosity index, determine whether there is a speed mismatch caused by changes in the viscoelasticity of the material;

[0067] S4: When there is a speed mismatch, calculate the initial feed speed of the forming mechanism based on the actual moving speed;

[0068] S5: Monitor the material accumulation level in the transition area between the material conveying mechanism and the forming mechanism. When the material accumulation level reaches the preset condition, drive the forming mechanism to start running at the initial feed speed.

[0069] S6: After the forming mechanism is started, the actual moving speed and the initial feed speed are adjusted in coordination based on the actual moving speed until the target production cycle is reached.

[0070] The material conveying mechanism is mainly responsible for outputting the mixed medicine into continuous material strips through mechanical extrusion and other methods. The forming mechanism is responsible for receiving the material strips and cutting and rolling them into round pellets of specified weight and shape.

[0071] The apparent viscosity index is a quantitative indicator used to assess changes in the rheological properties of materials online, reflecting the flow resistance of materials under specific driving conditions. For example, when the driving torque and die pressure increase while the actual flow rate decreases, it usually means that the apparent viscosity index increases, indicating that the current batch of material is more viscous and more difficult to flow.

[0072] Speed ​​mismatch refers to an imbalance between the actual feeding speed of the material conveying mechanism and the expected consumption speed of the molding mechanism, particularly a situation where supply falls short of demand. This application focuses on negative mismatch, i.e., a situation where the consumption rate of the molding mechanism is faster than the feeding rate of the material conveying mechanism. Conversely, if the feeding speed is higher than the molding consumption rate, accumulation will form in the transition area. This accumulation is not always considered abnormal in this application, but can be used as a start-up buffer within a controlled range.

[0073] In step S1, the trial run time is preferably set to cover the complete observation period from the start-up of the material conveying mechanism and the establishment of extrusion pressure to the stable outflow of material strips. If there is a significant mechanical acceleration phase or material filling phase after the equipment starts up, the trial run time should at least cover the stable output phase after that phase.

[0074] Preset parameters include the target rotational speed of the material conveying mechanism, the start-stop method, and the acceleration slope when necessary. When acquiring the actual moving speed of the material, priority is given to collecting speed values ​​at multiple consecutive moments, and the obvious fluctuations at the moment the material just exits the conveyor are removed. The remaining stable data is then used as the basis for subsequent judgment. The reason for this approach is that the material has not yet fully established stable internal pressure at the beginning of a batch change. If the instantaneous speed at the moment of start-up is used directly, transient fluctuations may be misjudged as the actual feeding capacity.

[0075] In one specific embodiment, the preset parameter can be the historical operating speed of the previous batch of similar products during the stable continuous production phase. "Similar products" preferably refers to batches of products with the same or similar formulation system, pellet weight specifications, die structure, and molding mechanism structure, rather than arbitrary historical batches.

[0076] When retrieving historical operating speeds, the system prioritizes reading the average speed or stable range speed of the corresponding batch during the stable production phase from the batch database of the equipment control system, and uses this as the initial reference value for trial operation. If multiple reference batches exist in the database, the batch with the closest formula to the current batch, the most recent production, and stable production quality is selected as the reference.

[0077] The actual moving speed can be obtained by installing a non-contact laser Doppler velocimeter directly below the output end of the material conveying mechanism. The Doppler frequency shift effect is used to illuminate the surface of the extruded material strip in real time, thereby calculating the actual outflow linear velocity of the material strip.

[0078] To ensure that the speed measurement results can be used for control, the speed meter should preferably be installed in a location that avoids the area of ​​strong reflection and obvious shaking when the material just exits the die. It is usually set in the free section after the material strip leaves the die and before it enters the forming mechanism, so that it can reflect the true outflow speed and is not easily affected by the traction of the forming mechanism.

[0079] Furthermore, the preferred process for obtaining the actual moving speed includes: after the trial run begins, a start-up transition phase is initiated; once continuous material flow is detected, speed measurement data is started; subsequently, multiple speed values ​​are recorded during the continuous sampling period; obviously abnormal jump values ​​are then removed; finally, a representative value from the stable phase is taken as the actual moving speed. For example, if the speed fluctuates significantly in the early stage of continuous sampling and tends to stabilize in the later stage, it is preferable to use the representative value of the stable later stage as the input for subsequent steps, rather than using the average value over the entire period. This avoids interference from the start-up transients on subsequent apparent viscosity index and speed mismatch judgments.

[0080] In step S2, the driving torque, output material pressure, and actual moving speed are jointly analyzed to obtain an apparent viscosity index that can characterize the current material flow resistance level.

[0081] Specifically, the formula for calculating the apparent viscosity index is: Apparent viscosity index = (driving torque * material pressure) / actual moving speed.

[0082] Among them, the driving torque is the power input provided by the material conveying mechanism to overcome the internal friction and mechanical friction of the material. The driving torque can be obtained by a torque sensor installed on the drive motor of the material conveying mechanism.

[0083] Material pressure is the internal resistance state of material accumulating at the front end of the die. This parameter can be obtained by a pressure sensor installed at the end of the barrel, the front of the die, or the connecting flow channel. The installation position of the pressure sensor should preferably be selected in a position that can reflect the extrusion resistance and is not easily affected by local dead corners and material blockage. A diaphragm structure can also be used to prevent highly viscous materials from directly contaminating the sensing unit.

[0084] The actual moving speed can be obtained by setting a non-contact linear velocity detection unit on the exposed section of the material strip. For example, by using machine vision, displacement tracking can be performed on the natural texture or slightly textured points on the surface of the material strip, and the displacement changes between adjacent images can be continuously acquired to calculate the actual moving speed.

[0085] Multiplying the driving torque by the material pressure as the numerator means that the dual increase in power input and internal resistance will significantly amplify the apparent viscosity index; using the actual moving speed as the denominator means that under the same power and resistance, the slower the flow speed, the higher the apparent viscosity index of the material.

[0086] To facilitate continuous online use, the control system can synchronously read these three parameters within the same sampling period, and perform time alignment and outlier checks after reading to avoid distortion of the apparent viscosity index due to inconsistent sampling times.

[0087] After obtaining the apparent viscosity index of the current batch of material, relying solely on absolute values ​​of this single batch's data for judgment is susceptible to interference from long-term, slowly changing factors such as equipment wear and environmental temperature fluctuations, leading to misjudgments. To improve the accuracy and robustness of the judgment, a reliable reference benchmark needs to be introduced to identify abrupt changes in material properties through relative comparison. In a preferred embodiment of this application, step S3 includes:

[0088] S31: Obtain the apparent viscosity index of the previous batch of material as the baseline viscosity index;

[0089] S32: Compare the actual moving speed with the preset forming feed speed, and compare the apparent viscosity index with the reference viscosity index. The preset forming feed speed is the target feed speed required by the process.

[0090] S33: If the actual moving speed is less than the preset forming feed speed and the apparent viscosity index is greater than the reference viscosity index, it is determined that there is a speed mismatch caused by the change in material viscoelasticity.

[0091] S34: If the actual moving speed is greater than or equal to the preset forming feed speed, or the apparent viscosity index is less than or equal to the reference viscosity index, it is determined that there is no speed mismatch caused by changes in the viscoelasticity of the material.

[0092] S35: When there is no speed mismatch, the preset forming feed speed is used as the initial feed speed.

[0093] In this specific implementation plan, the apparent viscosity index of the previous batch of material refers to the material characteristic data recorded under stable operating conditions before the equipment changed material batches. Using it as the benchmark viscosity index can effectively filter out the substrate drift caused by long-term aging of the equipment.

[0094] To make the benchmark viscosity index more representative, multiple consecutive sampling values ​​from the previous batch after it entered stable production can be selected first, and data from the start-up and shutdown phases, alarm phases, and phases with obvious abnormal fluctuations can be removed before generating the representative value for this batch.

[0095] The preset forming feed rate is the target feed rate specified in the process formula. This preset value is usually pre-stored in the equipment formula management module and is managed in association with pellet size, target gram weight per pellet, material formula, and mold parameters; when switching to the corresponding production task, the control system automatically calls up the preset forming feed rate.

[0096] Step S33 sets a dual trigger condition: it requires both a macroscopic physical phenomenon of supply falling short of demand (actual moving speed less than the preset forming feed speed) and a microscopic internal cause of material viscosity increase (apparent viscosity index greater than the reference viscosity index). Only when both conditions are met simultaneously can it be concluded that the current insufficient speed is more likely due to increased viscoelasticity of the material than to occasional mechanical disturbances.

[0097] Step S34 covers other operating conditions where fluctuations are caused by normal or non-viscoelastic factors. Step S35 clarifies the default execution logic when viscoelasticity does not cause mismatch. To further improve the stability of the judgment, the control system may require the judgment result corresponding to step S33 or step S34 to appear continuously for several sampling periods before it officially takes effect, avoiding frequent switching of judgment results caused by single sampling jitter.

[0098] During actual production batch changes, the method of this application first retrieves the average apparent viscosity index (e.g., 3.0) of the previous batch during the stable production phase from the historical database as the baseline viscosity index. Simultaneously, it reads the preset molding feed rate required by the current process formulation (e.g., 12 m / min). During the trial operation phase, the system measures the actual moving speed of the current batch of material as 9 m / min and calculates the current apparent viscosity index as 4.5.

[0099] Then the comparison logic is executed: it is found that 9 m / min is less than 12 m / min and 4.5 is greater than 3.0, which satisfies the dual conditions of step S33. Therefore, it is determined that there is a speed mismatch caused by the change in material viscoelasticity, and then the initial feed rate is recalculated.

[0100] Conversely, if the measured actual moving speed is 11 m / min, but the apparent viscosity index is only 2.8 (less than 3.0), it indicates that the low speed may be due to incomplete stabilization during startup or other non-material factors. In this case, the condition of step S34 is met, and it is determined that there is no speed mismatch caused by changes in the material's viscoelasticity. According to step S35, the system will directly adopt 12 m / min as the initial feed speed of the molding mechanism. Furthermore, at the database implementation level, the apparent viscosity index, collection time, formula number, ambient temperature range, and equipment number for each batch can be stored together to form a traceable historical record. When executing step S31, the system prioritizes retrieving the historical record closest to the current production conditions, thereby improving the reference value of the benchmark viscosity index.

[0101] It should be noted that, even without speed mismatch, the equipment still faces dynamic disturbances from startup to steady-state operation, such as slight differences between material batches, equipment temperature variations, and power grid fluctuations. These factors can cause a slow drift in the actual matching relationship between extrusion and shot rubbing. Therefore, the control system still needs to use the degree of material accumulation in the transition zone (such as the length of the buffer arc) as a feedback indicator to continuously fine-tune the shot rubbing speed in a closed loop, ensuring that the actual operating speed of the forming mechanism remains near the target feed speed. This adjustment does not change the target feed speed required by the process, but rather counteracts dynamic disturbances near the target feed speed, thereby ensuring the long-term stability of the matching relationship throughout the entire batch production process.

[0102] Having clarified that there is a velocity mismatch caused by changes in the viscoelasticity of the material, in order to set the initial feed speed of the molding mechanism more scientifically and dynamically, step S4 further includes:

[0103] S41: Calculate the difference between the apparent viscosity index and the reference viscosity index, and calculate the ratio of the difference to the apparent viscosity index to obtain the safety factor;

[0104] S42: Multiply the safety factor by the actual moving speed to obtain the initial feed speed of the forming mechanism.

[0105] In this specific implementation scheme, the difference reflects the absolute degree to which the current batch of material is more viscous than historically stable batches. Dividing this difference by the current apparent viscosity index converts this absolute degree into a relative dimensionless proportion, i.e., a safety factor.

[0106] This safety factor dynamically reflects the increase in material flow resistance. The more viscous the material, the larger the calculated difference, and the more adaptively the resulting safety factor (i.e., the rate of decrease) matches the current resistance state.

[0107] Multiplying this safety factor by the actual moving speed means that the initial feed rate of the forming mechanism will be adaptively discounted according to the severity of the material's viscosity. In the actual control program, the system automatically reads the apparent viscosity index and reference viscosity index obtained in steps S2 and S3, performs the above four arithmetic operations, and can output the initial feed rate command specific to the current batch of material in real time.

[0108] In step S5, the material accumulation level is such that a buffer sufficient to absorb short-term material supply fluctuations has been formed within the transition area. This buffer does not require the formation of a large volume of material, but rather that after the forming mechanism is started, even if there are short-term minor fluctuations in the material conveying mechanism, the forming mechanism will not immediately drag the material strip due to a lack of material.

[0109] Furthermore, step S5 includes:

[0110] S51: Real-time monitoring of the lowest point of the material's sag arc within the transition area;

[0111] S52: Calculate the current depth value of the material's sag arc based on the lowest point position;

[0112] S53: Compare the current depth value with the preset minimum safety buffer depth threshold;

[0113] S54: When the current depth value is greater than or equal to the minimum safe buffer depth threshold, it is determined that the material accumulation degree has reached the preset condition, and the forming mechanism is driven to start running at the initial feed speed.

[0114] The degree of material accumulation can be monitored in real time by a photoelectric array sensor installed below the transition area to monitor the lowest point of the material strip's sag. When the sag of the material strip reaches a set depth threshold, it is determined that the material accumulation has reached the preset condition, and only then is a start command sent to the forming mechanism.

[0115] The sag can be understood as the natural drooping shape formed by the material strip under the combined action of its own weight and the speed difference between the front and rear. When the front material conveying mechanism continuously supplies material while the rear forming mechanism has not yet started, the material strip will gradually sag in the transition area; the more obvious the sag, the more sufficient the buffering capacity.

[0116] To make this judgment feasible, the photoelectric array sensor is preferably arranged with multiple detection points along the vertical direction to identify the height range of the lowest point of the material strip. The control system can determine whether the current lowest point has reached a preset depth threshold based on the combination of obscured detection points. This preset depth threshold is preferably obtained through trial operation and tuning. The tuning method can be: start the forming mechanism at different droop depths and observe whether dragging, intermittent feeding, or excessive accumulation occurs after startup; use the minimum droop depth that can stably achieve smooth material reception as the threshold. If the equipment space is limited and it is inconvenient to arrange the photoelectric array sensor, a visual sensor, ultrasonic ranging sensor, or contact-type pendulum detection device can also be used to characterize the degree of accumulation, but the control logic is still to determine whether the transition area has formed a sufficient buffer.

[0117] In this specific implementation, as mentioned above, the lowest point position can be acquired in real time using a photoelectric array sensor. The system converts the acquired lowest point position coordinates into a physical distance relative to the horizontal baseline, thus obtaining the current depth value. The minimum safe buffer depth threshold is the minimum material reserve required to absorb the mechanical impact and short-term speed difference during the start-up of the molding mechanism.

[0118] The solution in this application continuously compares the real-time calculated current depth value with the threshold at high frequency. Only when the drooping depth of the material strip is greater than this safe depth threshold can the start command be released. If the current depth value fluctuates frequently around the depth threshold, the system can introduce a very short confirmation delay to ensure that the material strip has indeed reached a stable safe buffer state before executing step S54.

[0119] The technical advantage of this solution is that it eliminates the subjective arbitrariness of manual visual observation, ensuring that the transition area has sufficient and consistent buffer margins when each batch is started, preventing material snatching in the forming mechanism, and laying an extremely stable initial state for subsequent step-by-step acceleration.

[0120] In step S6, when coordinating the adjustment of the actual moving speed and the initial feed speed, a progressive adjustment method is preferred, with the material conveying mechanism taking the lead and the forming mechanism following suit. This ensures that both mechanisms undergo status confirmation after each speed-up before proceeding to the next, until the target production cycle time is met. The reason for this setup is that the highly viscoelastic material after batch change is sensitive to changes in rotational speed. If both mechanisms simultaneously increase speed rapidly at fixed steps, although it may superficially approach the target cycle time faster, it can actually create additional resistance inside the barrel that has not yet been released, leading to an upward surge in pressure at the die opening, an increase in drive torque, and even causing the forming mechanism to again pull on the material strip that has not yet been stably supplied. In contrast, confirming first that the material conveying mechanism has stabilized its supply at the new speed level, and then updating the feed speed of the forming mechanism accordingly, allows the increase in supply capacity to precede the increase in consumption capacity, thereby maintaining a controlled buffer state in the transition zone.

[0121] Furthermore, step S6 includes:

[0122] S61: After the forming mechanism is started, the actual moving speed is gradually increased according to the preset stabilization time, based on the actual moving speed, to obtain a new actual moving speed.

[0123] S62: Within a preset stabilization time, monitor whether the driving torque of the material conveying mechanism and the material pressure at the output end are both within the corresponding safety threshold.

[0124] S63: If all are within the corresponding safety threshold, then calculate the updated feed speed of the forming mechanism based on the new actual moving speed.

[0125] S64: Repeat steps S61 to S63 until the new actual moving speed and the updated feed speed together reach the target production cycle time; wherein, the target production cycle time is the target production speed required by the process.

[0126] In step S61, the gradual increase in speed involves increasing the speed by a small increment each time. After each increase, the speed is not immediately increased further; instead, an observation phase begins. This speed increment is not limited to a specific value, but its magnitude should meet two conditions: first, it should be sufficient to produce a identifiable change in the material supply capacity; second, it should not cause a significant impact due to an excessively large single speed increase. The preset stabilization time preferably covers the observation process after the speed increase, during which the pressure inside the barrel is re-established, the die outlet flow stabilizes, and the sensor output becomes stable.

[0127] The safety thresholds in step S62 include thresholds set independently for drive torque and material pressure, and their setting basis should be derived from the equipment's allowable load range, long-term stable operation experience, and material quality and safety requirements.

[0128] If the equipment control system already has motor overload protection thresholds and die pre-pressure alarm thresholds, the safety thresholds in this application are preferentially set before the formal protection thresholds, serving as early warning and flexible adjustment boundaries, rather than waiting for the hardware protection to take effect before processing.

[0129] It should be noted that although the material may not show a significant temperature rise as visible to the temperature sensor during high-resistance extrusion, the sustained high torque and high pressure usually mean stronger friction and shearing, which increases the risk of localized heating and changes in properties. Therefore, using torque and pressure as safety monitoring parameters is of direct significance.

[0130] In step S63, the updated feed rate still follows the principle of not exceeding the new actual moving speed, and can continue to be updated using the safety ratio coefficient in step S4. If the buildup in the transition region is still sufficient, the updated feed rate can be closer to the new actual moving speed; if the buildup has been significantly reduced, it is preferable to retain a larger safety margin.

[0131] In step S63, only after confirming that the acceleration has not triggered abnormal resistance within a preset stabilization time is the measured new actual moving speed used as a benchmark to recalculate and issue the updated feed speed to the forming mechanism. This step-by-step acceleration and status confirmation mechanism ensures that each speed increase occurs within the safety boundaries of the equipment and materials. This not only prevents localized stretching or accumulation due to asynchronous responses during acceleration but also effectively avoids mechanical damage to the equipment or material denaturation due to excessive friction and heat caused by blind acceleration, guaranteeing the smoothness and safety of the production capacity recovery process.

[0132] During the aforementioned step-by-step speed increase and monitoring process, if the material has extremely high local viscosity or contains incompletely crushed hard lumps, even with gradual speed increase, the drive torque or material pressure may exceed the safety threshold within the preset stabilization time. In this case, directly implementing emergency shutdown measures would lead to frequent production interruptions, increasing the burden of manual barrel cleaning and material waste. Therefore, a self-healing mechanism that can automatically attempt recovery when an anomaly occurs is needed.

[0133] In some preferred embodiments, step S62 is followed by:

[0134] S621: If either the driving torque or the material pressure exceeds the corresponding safety threshold, the actual moving speed of the material conveying mechanism is reduced to the preset safety speed, and the feeding speed of the forming mechanism is reduced simultaneously; the preset safety speed is half of the current actual moving speed.

[0135] S622: If the driving torque and material pressure are both within the corresponding safety threshold when running at the preset safe speed, the preset safe speed will be increased back to the actual moving speed before the deceleration.

[0136] S623: If the number of consecutive speed reduction operations reaches the warning count and the drive torque or material pressure still exceeds its corresponding safety threshold, a shutdown alarm will be triggered.

[0137] The preset safety speed is a retraction speed lower than the current actual moving speed, used to quickly reduce the resistance inside the barrel and restore a stable discharge state. This preset safety speed can be pre-set to half of the current actual moving speed. However, in some preferred embodiments, the preset safety speed can be pre-set to the current actual moving speed multiplied by a retraction coefficient M, where M is a coefficient greater than 0 and less than 1. The reason for not directly limiting it to a fixed ratio is that different machine models, different die sizes, and different material systems have different sensitivities to the speed reduction magnitude. Using an adjustable retraction coefficient is more conducive to adapting to the actual equipment. Synchronously reducing the feed speed of the forming mechanism is to avoid the forming end maintaining a high consumption rhythm after the feeding end speeds up, thus preventing dragging again.

[0138] In step S622, the recovery process is preferably not a one-time recovery, but a gradual recovery in the same manner as in step S61. That is, the system first confirms that the anomaly has been resolved, and then gradually returns to the speed level before the deceleration, to avoid triggering the over-limit again immediately after recovery.

[0139] In step S623, the number of warnings is not limited to a fixed value, but can be preset to a number N based on the equipment's fault tolerance, material value, and production continuity requirements. The preferred principle for setting the number N is to allow for automatic recovery opportunities for momentary anomalies, while avoiding keeping the equipment in a high-risk load state for a long time due to repeated retries.

[0140] In this specific implementation scheme, when the scheme detects excessive pressure or torque, the actual moving speed is immediately reduced to a preset safe speed, entering a low-load discharge mode. Simultaneously, the forming mechanism must also reduce its speed to maintain the bearing balance in the transition zone. The reason for adopting a deceleration-first, observation-later approach is that many batch change anomalies are not true mechanical failures, but rather momentary over-limits caused by localized high-resistivity material clumps, short-term uneven distribution, or hard particles passing through high-resistivity areas. By actively reducing speed, the shear strength inside the barrel and the back pressure before the die opening can be reduced, allowing abnormal material to continue being ejected under milder operating conditions.

[0141] If, after operating at a safe speed for a period of time, the excessive pressure or torque returns to the normal range, it indicates that the abnormal material causing the sudden change in resistance has been successfully discharged, or the pressure distribution inside the barrel has stabilized again. The system will automatically return to the operating state before the speed reduction and continue to attempt subsequent speed-up processes. To avoid recovery being too rapid, it is preferable to reconfirm before recovery that the transition area still has a basic buffer capacity and that the forming mechanism does not show obvious signs of material shortage.

[0142] If repeated attempts at low-speed material discharge fail to restore pressure or torque to normal, it indicates a potential for persistent material abnormalities, die blockage, or mechanical jamming. In this case, the system will completely cut off power and trigger an alarm, requiring manual intervention.

[0143] By introducing a self-healing logic of deceleration and retry, the system can automatically attempt troubleshooting when faced with instantaneous high resistance conditions, minimizing unnecessary downtime and ensuring production continuity. Simultaneously, the pre-set number of warnings ensures that in the event of a serious fault that cannot be automatically recovered from, the system can be shut down promptly to protect the equipment from physical damage, achieving an effective balance between production efficiency and equipment safety.

[0144] Furthermore, step S64 includes:

[0145] S65: After reaching the target production cycle, it enters the continuous forming stage and collects the material sag arc value in the transition area in real time during the continuous forming stage.

[0146] S66: Calculate the length deviation between the material's sag radius value and the target radius reference value;

[0147] S67: The feed speed fine-tuning amount is calculated based on the length deviation using the proportional integral differential algorithm. The feed speed fine-tuning amount is then added to the current feed speed of the forming mechanism to obtain the real-time feed speed.

[0148] S68: Drives the forming mechanism to operate at a real-time feed rate.

[0149] In this specific implementation, the material sag arc value refers to the vertical distance between the lowest point of the material strip's natural sag in the transition area and the horizontal baseline. This value directly reflects the material buffer amount in the current transition area. To ensure that this value can be repeatedly collected, the horizontal baseline can be pre-set as the line connecting the material conveying mechanism's discharge point and the forming mechanism's inlet point, or as a calibration baseline fixedly installed on the equipment frame.

[0150] During equipment installation and commissioning, the camera field of view calibration and baseline calibration can be completed under no-load conditions first, and then the baseline parameters can be written into the control system so that they can be directly called in the continuous forming stage.

[0151] The target curvature reference value is the optimal sag depth determined during equipment debugging or historical stable production. It represents an ideal buffer state that avoids both dragging and excessive accumulation. This target curvature reference value can be obtained by: continuously recording the material sag curvature value in the transition area, the corresponding single-pill weight fluctuation of the large honey pills, and the appearance pass rate after several complete production cycles of stable equipment production; selecting the working condition range with the most stable weight and the best appearance quality; and determining the average sag depth within this range as the target curvature reference value; alternatively, a verified and effective reference value can be directly retrieved from historical stable production batches as the default parameter for the current formula.

[0152] The length deviation is the difference between the actual droop curvature and the ideal state. A positive value usually indicates excessive accumulation, while a negative value indicates insufficient buffering. To prevent interference from transient noise, several consecutive sampling points can be smoothed before calculating the length deviation. For example, the median or moving average of the curvature values ​​corresponding to several consecutive frames can be used to obtain a more stable current curvature value before comparison.

[0153] The proportional-integral-derivative (PI) algorithm, also known as the classic PID closed-loop control algorithm, calculates the compensation amount based on the magnitude, direction, and trend of the deviation. Here, the proportional component is used to respond immediately to the current deviation, the integral component is used to handle persistent small deviations, and the derivative component is used to anticipate the trend of deviation changes and suppress overshoot.

[0154] The feed rate fine-tuning is a speed correction value derived from the above algorithm, used to make minor adjustments to the current operating speed of the forming mechanism. To ensure smooth adjustment, the control system usually sets upper and lower limits for the feed rate fine-tuning and can also set a limit on the rate of change of a single adjustment to avoid sudden acceleration or deceleration of the forming mechanism during continuous forming.

[0155] In one specific implementation, assuming the target curvature reference value is 50mm, if the currently collected material sag curvature value is 55mm, the length deviation is calculated to be +5mm. The control system inputs this +5mm deviation to the built-in PID controller, calculating a feed speed fine-tuning amount of +0.2 rpm. Subsequently, the system adds this +0.2 rpm to the current feed speed of the forming mechanism (e.g., 60 rpm) to obtain a real-time feed speed of 60.2 rpm, and drives the forming mechanism to run at this speed, thereby slightly accelerating the consumption rhythm and gradually reducing the sag curvature to 50mm. In this implementation scenario, the control system can also set an allowable fluctuation range. For example, when the material sag curvature value is within a small range near the target curvature reference value, no new feed speed fine-tuning amount is output to reduce frequent actuator movements; only when the deviation continuously exceeds the allowable fluctuation range and reaches a preset duration is the adjustment output initiated, thus balancing response speed and control stability.

[0156] Furthermore, in step S67, the calculation of the feed rate fine-tuning amount based on the length deviation using the proportional-integral-differential algorithm includes the following steps:

[0157] S671: Perform time integration and time differentiation calculations on the length deviation to obtain the cumulative amount of length deviation and the rate of change of length deviation.

[0158] S672: Multiply the length deviation, the cumulative length deviation, and the cumulative length deviation by the corresponding proportional coefficient, integral coefficient, and differential coefficient respectively, and then sum them to obtain the feed rate fine adjustment.

[0159] In this specific implementation, time integration refers to accumulating the length deviation over a period of time to reflect the degree of accumulation of the deviation, i.e., the cumulative amount of the length deviation. During program implementation, an accumulation register can be set up inside the controller. Each time a sampling cycle occurs, the current length deviation is sequentially added to this register. When the deviation persists continuously, the value in the register will gradually increase, indicating that the system's long-term deviation from the target radian reference value is increasing. To avoid over-adjustment due to long-term accumulation, upper and lower limits can be set for the accumulation register, or the accumulated amount can be gradually released after the deviation enters the allowable fluctuation range.

[0160] The time derivative calculates the change in length deviation per unit time, reflecting the trend of the deviation, i.e., the rate of change of the length deviation. In the program implementation, the length deviation of the current sampling period and the length deviation of the previous sampling period can be recorded. By comparing the two, it can be determined whether the deviation is increasing rapidly, decreasing gradually, or remaining stable. To reduce the amplification effect of noise on the derivative, the length deviation sequence can be simply filtered before calculating the rate of change.

[0161] The proportional gain, integral gain, and derivative gain are the three core gain parameters in a PID algorithm, determining the system's response strength to current deviation, historical cumulative deviation, and future deviation trends, respectively. These three parameters can be obtained during equipment commissioning through trial runs: first, fix a small integral and derivative gain, gradually adjust the proportional gain, and observe the speed and oscillation of the material's sag arc returning to the target arc reference value; then, after the proportional gain is basically appropriate, introduce the integral gain to reduce long-term residual deviation; finally, introduce the derivative gain to suppress overshoot. During commissioning, the material's sag arc recovery time, fluctuation amplitude, and the stability of the large honey pellet's weight can be used as evaluation criteria. Multiplying these three parts by their corresponding coefficients and summing them yields the feed rate fine-tuning amount.

[0162] Please refer to Figure 2This application also proposes a control system for the forming process of large honey pills, characterized in that, for implementing any of the above methods, the system includes:

[0163] Acquisition Module 201: During the production batch changeover start-up phase, the drive material conveying mechanism operates according to preset parameters within the trial operation time and acquires the actual moving speed of the material;

[0164] First calculation module 202: Calculates the apparent viscosity index of the current batch of material based on the driving torque of the material conveying mechanism, the material pressure at the output end, and the actual moving speed.

[0165] Judgment module 203: Based on the actual moving speed and apparent viscosity index, determine whether there is a speed mismatch caused by changes in the viscoelasticity of the material;

[0166] Second calculation module 204: When there is a speed mismatch, calculate the initial feed speed of the forming mechanism based on the actual moving speed;

[0167] Drive module 205: Monitors the material accumulation level in the transition area between the material conveying mechanism and the forming mechanism. When the material accumulation level reaches the preset condition, it drives the forming mechanism to start running at the initial feed speed.

[0168] Adjustment module 206: After the forming mechanism is started, it adjusts the actual moving speed and the initial feed speed in a coordinated manner based on the actual moving speed until the target production cycle is reached.

[0169] In this system architecture, the various functional modules cooperate to form a complete closed-loop control network. The acquisition module 201 is responsible for the accurate collection of front-end physical data, providing factual basis for subsequent decision-making; the first calculation module 202 and the judgment module 203 can calculate the apparent viscosity index of the material and, based on this key parameter, identify whether the material characteristics after batch change affect the actual material movement speed, causing speed mismatch between the material output mechanism and the forming mechanism; the second calculation module 204 is responsible for calculating the feeding speed of the forming mechanism when an anomaly occurs; the drive module 205 strictly controls the start-up timing of the forming mechanism; and the adjustment module 206 is responsible for steadily promoting the full recovery of production capacity while ensuring safety. In practical applications, the above modules can be integrated into the same programmable logic controller (PLC) or industrial control computer, achieving seamless data flow through an internal high-speed bus.

[0170] The above technical solution highly integrates complex rheological characteristic analysis, adaptive parameter calculation, and multi-mechanism collaborative control logic into a single automated system. This system can independently complete the entire closed-loop control process, from anomaly identification to parameter reconstruction and smooth recovery, significantly reducing reliance on operator experience. Its unique technical advantage lies in endowing traditional large honey pellet machines with the intelligent ability to sense material changes and adapt autonomously, significantly improving the equipment's operational stability and first-pass yield in multi-variety, small-batch production scenarios.

[0171] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method for controlling the forming process of large honey pills, applied to a large honey pill machine, wherein the large honey pill machine includes at least a material conveying mechanism and a forming mechanism, characterized in that, The method includes the following steps: S1: During the production batch changeover start-up phase, the material conveying mechanism is driven to operate according to preset parameters within the trial operation period, and the actual moving speed of the material is obtained; S2: Calculate the apparent viscosity index of the current batch of material based on the driving torque of the material conveying mechanism, the material pressure at the output end, and the actual moving speed. S3: Based on the actual moving speed and the apparent viscosity index, determine whether there is a speed mismatch caused by changes in the viscoelasticity of the material; S4: When the speed mismatch exists, calculate the initial feed speed of the forming mechanism based on the actual moving speed; S5: Monitor the material accumulation level in the transition area between the material conveying mechanism and the forming mechanism. When the material accumulation level reaches the preset condition, drive the forming mechanism to start running according to the initial feed speed. S6: After the forming mechanism is started, the actual moving speed and the initial feed speed are adjusted in coordination based on the actual moving speed until the target production cycle is reached.

2. The method for controlling the forming process of large honey pills according to claim 1, characterized in that, Step S6 includes: S61: After the forming mechanism is started, the actual moving speed is gradually increased according to the preset stabilization time, based on the actual moving speed, to obtain a new actual moving speed; S62: Within a preset stabilization time, monitor whether the driving torque of the material conveying mechanism and the material pressure at the output end are both within the corresponding safety threshold. S63: If all are within the corresponding safety threshold, then calculate the updated feed speed of the forming mechanism based on the new actual moving speed; S64: Repeat steps S61 to S63 until the new actual moving speed and the updated feed speed together reach the target production cycle time; wherein, the target production cycle time is the target production speed required by the process.

3. The method for controlling the forming process of large honey pills according to claim 2, characterized in that, Step S62 is followed by: S621: If either the driving torque or the material pressure exceeds the corresponding safety threshold, the actual moving speed of the material conveying mechanism is reduced to a preset safety speed, and the feeding speed of the forming mechanism is reduced simultaneously; the preset safety speed is half of the current actual moving speed. S622: If the driving torque and the material pressure are both within the corresponding safety threshold when running at a preset safe speed, then the preset safe speed is increased back to the actual moving speed before the deceleration. S623: If the number of consecutive speed reduction operations reaches the warning count and the driving torque or the material pressure still exceeds its respective safety threshold, a shutdown alarm is triggered.

4. The method for controlling the forming process of large honey pills according to claim 2, characterized in that, Step S64 is followed by: S65: After reaching the target production cycle, the continuous forming stage is entered, and the material sag arc value of the transition area is collected in real time during the continuous forming stage. S66: Calculate the length deviation between the material's sag arc value and the target arc reference value; S67: Calculate the feed speed fine-tuning amount based on the length deviation using the proportional-integral-differential algorithm, and add the feed speed fine-tuning amount to the current feed speed of the forming mechanism to obtain the real-time feed speed; S68: Drive the forming mechanism to operate at the real-time feed speed.

5. The method for controlling the forming process of large honey pills according to claim 4, characterized in that, In step S67, the calculation of the feed rate fine-tuning amount based on the length deviation using the proportional-integral-differential algorithm includes the following steps: S671: Perform time integration and time differentiation calculations on the length deviation to obtain the cumulative amount of length deviation and the rate of change of length deviation respectively; S672: Multiply the length deviation, the cumulative length deviation, and the cumulative length deviation by the corresponding proportional coefficient, integral coefficient, and differential coefficient respectively, and then sum them to obtain the feed rate fine adjustment amount.

6. The method for controlling the forming process of large honey pills according to claim 1, characterized in that, In step S2, the apparent viscosity index is calculated as follows: Apparent viscosity index = (driving torque * material pressure) / actual moving speed.

7. The method for controlling the forming process of large honey pills according to claim 1, characterized in that, Step S3 includes: S31: Obtain the apparent viscosity index of the previous batch of materials as the baseline viscosity index; S32: Compare the actual moving speed with the preset molding feed speed, and compare the apparent viscosity index with the reference viscosity index, wherein the preset molding feed speed is the target feed speed required by the process. S33: If the actual moving speed is less than the preset forming feed speed and the apparent viscosity index is greater than the reference viscosity index, it is determined that there is a speed mismatch caused by changes in the viscoelasticity of the material. S34: If the actual moving speed is greater than or equal to the preset forming feed speed, or the apparent viscosity index is less than or equal to the reference viscosity index, then it is determined that there is no speed mismatch caused by changes in the viscoelasticity of the material. S35: When there is no speed mismatch, the preset forming feed speed is used as the initial feed speed.

8. The method for controlling the forming process of large honey pills according to claim 7, characterized in that, Step S4 includes: S41: Calculate the difference between the apparent viscosity index and the reference viscosity index, and calculate the ratio of the difference to the apparent viscosity index to obtain the safety factor; S42: Multiply the safety factor by the actual moving speed to obtain the initial feed speed of the forming mechanism.

9. The method for controlling the forming process of large honey pills according to claim 1, characterized in that, Step S5 includes: S51: Real-time monitoring of the lowest point of the material's sag arc within the transition area; S52: Calculate the current depth value of the material's sag arc based on the lowest point position; S53: Compare the current depth value with a preset minimum safety buffer depth threshold; S54: When the current depth value is greater than or equal to the minimum safety buffer depth threshold, it is determined that the material accumulation degree has reached the preset condition, and the forming mechanism is driven to start running according to the initial feed speed.

10. A control system for the forming process of large honey pills, characterized in that, The system, comprising the steps for implementing the method according to any one of claims 1-9, includes: Acquisition module: During the production batch changeover start-up phase, the material conveying mechanism is driven to operate according to preset parameters within the trial operation time, and the actual moving speed of the material is acquired; First calculation module: Calculates the apparent viscosity index of the current batch of material based on the driving torque of the material conveying mechanism, the material pressure at the output end, and the actual moving speed; Judgment module: Based on the actual moving speed and the apparent viscosity index, determine whether there is a speed mismatch caused by changes in the viscoelasticity of the material; Second calculation module: When the speed mismatch exists, calculate the initial feed speed of the forming mechanism based on the actual moving speed; Drive module: Monitors the material accumulation level in the transition area between the material conveying mechanism and the forming mechanism. When the material accumulation level reaches a preset condition, it drives the forming mechanism to start running at the initial feed speed. Adjustment module: After the forming mechanism is started, the actual moving speed is adjusted in conjunction with the initial feed speed based on the actual moving speed until the target production cycle is reached.

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