A production control system and method for plastic particles

Abstract

The application relates to the technical field of plastic product production control, and discloses a plastic particle production control system and method. First, raw material supply data, raw material quality data and production equipment operation data in a plastic particle production process are acquired, and raw material production feature data is generated; then, based on the raw material production feature data, a collaborative analysis is performed on a batching process, a mixing process and a melting extrusion process, and a process control parameter set is generated; then, the production equipment is dynamically adjusted according to the process control parameter set, and a particle quality evaluation result is generated in combination with production feedback data; finally, production optimization control instructions are generated according to the particle quality evaluation result, and closed-loop control of the production process is realized. The application can realize collaborative management of raw material analysis, process control, quality evaluation and optimization decision, and improve the stability, consistency and production efficiency of the plastic particle production process.

Description

Technical Field

[0001] This invention relates to the field of plastic product manufacturing control technology, and in particular to a production control system and method for plastic particles. Background Technology

[0002] Plastic pellets are a crucial raw material for plastic product manufacturing, and their production process typically involves multiple steps, including raw material transportation, batching and mixing, melt extrusion, and pelletizing. Because the performance and quality of plastic pellets directly affect subsequent processing steps such as injection molding, blow molding, and extrusion molding, the production process requires strict control over raw material quality, process parameters, and equipment operating conditions. Currently, most plastic pellet production lines rely primarily on preset process parameters for production control. When changes occur in raw material batches, raw material quality, or equipment operating conditions, it is often difficult to adjust production parameters in a timely manner, easily leading to problems such as product quality fluctuations, decreased production efficiency, and increased energy consumption.

[0003] Meanwhile, in existing plastic pellet production management methods, raw material data, equipment data, and quality inspection data are mostly managed in a decentralized manner. There is a lack of effective data correlation and collaborative analysis mechanisms between different production stages, making it difficult to fully utilize feedback information generated during production. When product quality abnormalities occur, it is difficult to quickly locate influencing factors and optimize parameters in a timely manner, failing to form a closed-loop control mechanism for the production process. This affects the stability, consistency, and production management level of plastic pellet production. Therefore, there is an urgent need for a plastic pellet production control system and method that can achieve closed-loop management of raw material status analysis, process collaborative control, quality assessment, and production optimization. Summary of the Invention

[0004] To achieve the above-mentioned objectives, the present invention provides the following technical solution: a method for controlling the production of plastic particles, comprising the following steps: Step S1: Obtain raw material supply data, raw material quality data, and production equipment operation data during the plastic particle production process. Collect, analyze, and standardize the raw material supply data, raw material quality data, and production equipment operation data in a unified manner to generate raw material production characteristic data. Step S2: Based on the raw material production characteristic data, perform a collaborative analysis of the batching process, mixing process, and melt extrusion process in the plastic particle production process, establish production process execution status information, and generate a set of process control parameters based on the production process execution status information. Step S3: Based on the process control parameter set, dynamically adjust the temperature control unit, pressure control unit, and extrusion control unit in the plastic particle production process, and obtain the adjusted production process feedback data in real time. Perform quality correlation analysis on the production process feedback data to generate particle quality assessment results. Step S4: Based on the particle quality assessment results, comprehensively evaluate the operating status of the production equipment, the process execution status, and the product quality status, generate production optimization control instructions, and feed the production optimization control instructions back to the production process for closed-loop control to achieve continuous and stable production of plastic particles.

[0005] Preferably, step S1 further includes: The detection devices installed in the raw material storage area, conveying area and batching area acquire batch information, type information, moisture content information, particle size information and auxiliary material addition information of plastic resin raw materials, and acquire the operating status information of conveying equipment, metering equipment and mixing equipment. All acquired data are processed synchronously according to a unified time benchmark, and the correlation between raw material data is established. A raw material production dataset is constructed based on the source of raw materials, the quality of raw materials, and the operating status of equipment. The raw material production dataset is then standardized and its features are classified to generate raw material production feature data that can characterize the composition, quality, and supply status of raw materials.

[0006] Preferably, step S2 further includes: Based on the raw material production characteristic data, a production process matching relationship is established. A batching execution plan is generated according to the raw material type, auxiliary material composition, and target product specifications. Based on the batching execution plan, various raw materials are controlled to enter the mixing equipment for mixing. The operating status information of the mixing process is acquired in real time. Then, the raw material dispersion uniformity and melt preparation status are analyzed based on the mixing status information. Further, the melt flow status information and melt homogenization status information of the melt extrusion process are acquired. Finally, the process execution status information is established by combining the raw material production characteristic data, mixing status information, and melt status information, and a process control parameter set consisting of corresponding temperature control parameters, pressure control parameters, and extrusion speed control parameters is generated.

[0007] Preferably, step S3 further includes: The plastic particle production equipment is dynamically controlled according to the process control parameter set. The operating status of each temperature zone of the extrusion equipment is adjusted by the heating control mechanism, the operating pressure inside the extrusion channel is adjusted by the pressure control mechanism, and the screw speed, feeding speed and traction speed are adjusted by the drive control mechanism. During the production process, temperature feedback data, pressure feedback data, flow feedback data, and melt operation feedback data are collected in real time. At the same time, particle size information, particle shape information, and uniformity information in the pelletizing process are obtained. The obtained production feedback data is correlated with product quality data to form particle quality assessment results.

[0008] Preferably, step S4 further includes: Based on the particle quality assessment results generated in step S3, obtain the equipment operation status information, process execution status information, and product quality status information within the corresponding production cycle; Based on the particle quality assessment results, key production factors affecting product quality stability are identified, and a comprehensive production assessment result is established by combining equipment operating status, process execution status, and product quality status. Based on the comprehensive production assessment results, production optimization control instructions are generated and sent to the raw material supply link, process control link, and equipment execution link respectively. The raw material ratio, process parameters, and equipment operating parameters in the subsequent production process are dynamically optimized in real time to achieve closed-loop control of the plastic particle production process.

[0009] The present invention also provides a production control system for plastic particles, comprising the following modules: The production data construction module is used to acquire raw material data, equipment data, and production status data generated during the production of plastic particles, and to establish a unified data resource pool to form raw material production characteristic data. The process coordination and control module is connected to the production data construction module. It is used to receive raw material production characteristic data, coordinate the batching process, mixing process, melting process and extrusion process in the production process, and generate a set of process control parameters to realize dynamic control of the production process. The production optimization management module is connected to the production data construction module and the process collaborative control module, respectively. It is used to acquire production feedback data and product quality data, comprehensively evaluate the production process, and generate production optimization control instructions to realize adaptive closed-loop control of the plastic particle production process.

[0010] The production data construction module includes: The data construction unit is used to acquire raw material data, auxiliary material data, equipment operation data and production status data generated during the production of plastic particles, and to uniformly receive, synchronize, classify and organize and correlate the raw material data, auxiliary material data, equipment operation data and production status data to form a structured production dataset. The feature generation unit is used to establish the correlation between the raw material composition status, raw material quality status, raw material supply status and equipment operation status based on the structured production dataset, perform feature extraction and status characterization processing on the correlated data, generate raw material production feature data, and send the raw material production feature data to the process collaborative control module.

[0011] The process coordination and control module includes: The process analysis unit is used to receive raw material production characteristic data, perform correlation analysis on batching process, mixing process and melt extrusion process, establish process execution status information, and generate a set of process control parameters including temperature control parameters, pressure control parameters, feeding control parameters, screw speed control parameters and traction speed control parameters based on the process execution status information. The process control unit is used to receive a set of process control parameters and control the operation of the batching equipment, mixing equipment, extrusion equipment and pelletizing equipment according to the set of process control parameters. It dynamically adjusts the raw material feeding process, raw material mixing process, melt extrusion process and particle forming process, and at the same time acquires temperature feedback information, pressure feedback information, flow feedback information and equipment operation feedback information during the production process.

[0012] The production optimization management module includes: The quality decision unit is used to receive production feedback information and plastic particle quality inspection information, perform comprehensive analysis on the production feedback information and plastic particle quality inspection information, generate particle quality assessment results, and generate production optimization control instructions based on particle quality assessment results, equipment operating status information and process execution status information. The closed-loop control unit receives production optimization control commands and sends them to the production data construction module and the process coordination and control module. It dynamically corrects the raw material supply status, process execution status, and equipment operation status, while continuously receiving updated production data and feedback data. It tracks and manages the production optimization results, forming a closed-loop control system that links raw material analysis, process control, quality assessment, and optimization control, thereby achieving continuous and stable operation of the plastic particle production process.

[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention achieves collaborative management of raw material status and production status by uniformly collecting and correlating raw material supply data, raw material quality data, and equipment operation data, thereby improving the data utilization rate and production control accuracy of the production process.

[0014] This invention establishes a synergistic control mechanism among the batching process, mixing process, and melt extrusion process, which can dynamically generate process control parameters according to the production status, realize real-time optimization control of the production process, and improve the quality stability and product consistency of plastic particles.

[0015] This invention constructs a closed-loop control system for quality assessment and production optimization, enabling the linkage analysis between product quality status, process execution status, and equipment operation status. This system can promptly identify key factors affecting product quality and make dynamic adjustments, thereby improving production efficiency, reducing the risk of production fluctuations, and enhancing the continuous and stable operation capability of the plastic particle production process. Attached Figure Description

[0016] Figure 1 A flowchart illustrating the method steps provided in this application; Figure 2 A schematic diagram of the system modules provided in this application. Detailed Implementation

[0017] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0018] refer to Figure 1 This invention provides a method for controlling the production of plastic particles, including the following steps: Step S1: Obtain raw material supply data, raw material quality data, and production equipment operation data during the plastic particle production process. Collect, analyze, and standardize the raw material supply data, raw material quality data, and production equipment operation data in a unified manner to generate raw material production characteristic data. Step S2: Based on the raw material production characteristic data, perform a collaborative analysis of the batching process, mixing process, and melt extrusion process in the plastic particle production process, establish production process execution status information, and generate a set of process control parameters based on the production process execution status information. Step S3: Based on the process control parameter set, dynamically adjust the temperature control unit, pressure control unit, and extrusion control unit in the plastic particle production process, and obtain the adjusted production process feedback data in real time. Perform quality correlation analysis on the production process feedback data to generate particle quality assessment results. Step S4: Based on the particle quality assessment results, comprehensively evaluate the operating status of the production equipment, the process execution status, and the product quality status, generate production optimization control instructions, and feed the production optimization control instructions back to the production process for closed-loop control to achieve continuous and stable production of plastic particles.

[0019] First, the system acquires raw material supply data, raw material quality data, and production equipment operation data during the plastic particle production process. Specifically, the production control system obtains batch information, type information, moisture content information, particle size information, and auxiliary material addition information of plastic resin raw materials through data acquisition devices deployed in the raw material storage area, conveying area, and batching area. Simultaneously, it acquires the operating status information of conveying equipment, metering equipment, and mixing equipment. Subsequently, the production control system synchronously processes data from different equipment and different production stages according to a unified time base and establishes a correlation between raw material data and equipment data. Then, based on raw material source information, raw material quality information, and equipment operating status information, a raw material production dataset is constructed. This dataset is then classified, standardized, and categorized by status to generate raw material production characteristic data that reflects the composition, quality, and supply status of the raw materials. This raw material production characteristic data is then sent to subsequent process control stages.

[0020] Subsequently, based on the raw material production characteristic data generated in step S1, a process coordination analysis is performed on the plastic particle production process. Specifically, the production control system establishes a production process matching relationship based on the raw material production characteristic data, and generates a corresponding batching execution plan according to the raw material type, auxiliary material composition, and target product specifications. According to the batching execution plan, various raw materials are controlled to enter the mixing equipment for mixing, and the operating status information of the mixing equipment is collected in real time. The production control system further analyzes the uniformity of raw material dispersion and the melt preparation state based on the mixing state information, and obtains melt flow state information and melt homogenization state information during the melt extrusion stage. Then, combining the raw material production characteristic data, mixing state information, and melt state information, process execution state information is established, and a set of process control parameters consisting of corresponding temperature control parameters, pressure control parameters, and extrusion speed control parameters is generated, providing a control basis for subsequent production equipment adjustment.

[0021] Next, the plastic particle production equipment is dynamically adjusted according to the process control parameter set generated in step S2. Specifically, the production control system adjusts the operating status of each temperature zone of the extrusion equipment through the heating control mechanism, adjusts the internal operating pressure of the extrusion channel through the pressure control mechanism, and adjusts the screw speed, feeding speed, and traction speed through the drive control mechanism, so that the production equipment operates stably according to the process control parameter set. During the production process, temperature feedback data, pressure feedback data, flow feedback data, and melt operation feedback data are continuously acquired. At the same time, particle size information, particle shape information, and uniformity information in the pelletizing process are acquired. The production control system performs correlation analysis on the above production feedback data and product quality data to determine the degree of matching between the current production state and the target production state, thereby forming a particle quality assessment result, which is then sent to the production optimization stage.

[0022] Finally, the production process is comprehensively optimized based on the particle quality assessment results generated in step S3. Specifically, the production control system acquires equipment operating status information, process execution status information, and product quality status information within the current production cycle. Based on the particle quality assessment results, it identifies key production factors affecting product quality stability. Subsequently, it establishes a comprehensive production assessment result by combining the equipment operating status, process execution status, and product quality status. Based on the comprehensive production assessment result, it generates production optimization control instructions, which are sent to the raw material supply link, process control link, and equipment execution link to dynamically correct and continuously optimize the raw material ratio, process parameters, and equipment operating parameters. At the same time, the optimized production data is fed back to the production control system to participate again in the raw material characteristic analysis, process collaborative control, and quality assessment process. This forms a closed-loop control system that interconnects raw material analysis, process control, quality assessment, and optimization decision-making, achieving continuous and stable production of plastic particles and improving the quality consistency, production efficiency, and production process stability of plastic particles.

[0023] refer to Figure 2 This invention provides a production control method for plastic particles, comprising the following modules: The production data construction module is used to acquire raw material data, equipment data, and production status data generated during the production of plastic particles, and to establish a unified data resource pool to form raw material production characteristic data. The process coordination and control module is connected to the production data construction module. It is used to receive raw material production characteristic data, coordinate the batching process, mixing process, melting process and extrusion process in the production process, and generate a set of process control parameters to realize dynamic control of the production process. The production optimization management module is connected to the production data construction module and the process collaborative control module, respectively. It is used to acquire production feedback data and product quality data, comprehensively evaluate the production process, and generate production optimization control instructions to realize adaptive closed-loop control of the plastic particle production process.

[0024] The production data construction module includes: The data construction unit is used to acquire raw material data, auxiliary material data, equipment operation data and production status data generated during the production of plastic particles, and to uniformly receive, synchronize, classify and organize and correlate the raw material data, auxiliary material data, equipment operation data and production status data to form a structured production dataset. The feature generation unit is used to establish the correlation between the raw material composition status, raw material quality status, raw material supply status and equipment operation status based on the structured production dataset, perform feature extraction and status characterization processing on the correlated data, generate raw material production feature data, and send the raw material production feature data to the process collaborative control module.

[0025] The process coordination and control module includes: The process analysis unit is used to receive raw material production characteristic data, perform correlation analysis on batching process, mixing process and melt extrusion process, establish process execution status information, and generate a set of process control parameters including temperature control parameters, pressure control parameters, feeding control parameters, screw speed control parameters and traction speed control parameters based on the process execution status information. The process control unit is used to receive a set of process control parameters and control the operation of the batching equipment, mixing equipment, extrusion equipment and pelletizing equipment according to the set of process control parameters. It dynamically adjusts the raw material feeding process, raw material mixing process, melt extrusion process and particle forming process, and at the same time acquires temperature feedback information, pressure feedback information, flow feedback information and equipment operation feedback information during the production process.

[0026] The production optimization management module includes: The quality decision unit is used to receive production feedback information and plastic particle quality inspection information, perform comprehensive analysis on the production feedback information and plastic particle quality inspection information, generate particle quality assessment results, and generate production optimization control instructions based on particle quality assessment results, equipment operating status information and process execution status information. The closed-loop control unit receives production optimization control commands and sends them to the production data construction module and the process coordination and control module. It dynamically corrects the raw material supply status, process execution status, and equipment operation status, while continuously receiving updated production data and feedback data. It tracks and manages the production optimization results, forming a closed-loop control system that links raw material analysis, process control, quality assessment, and optimization control, thereby achieving continuous and stable operation of the plastic particle production process.

[0027] It should be noted that, unless otherwise specified, the embodiments and features and technical solutions in the embodiments of the present invention can be combined with each other.

[0028] Obviously, the embodiments described above are merely some embodiments of the present invention, not all embodiments. The accompanying drawings show preferred embodiments of the present invention, but do not limit the patent scope of the present invention. The present invention can be implemented in many different forms; rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing specific embodiments, or make equivalent substitutions for some of the technical features. Any equivalent structures made using the content of this specification and drawings, directly or indirectly applied to other related technical fields, are similarly within the patent protection scope of this invention.

Claims

1. A method for controlling the production of plastic particles, characterized in that, Includes the following steps: Step S1: Obtain raw material supply data, raw material quality data, and production equipment operation data during the plastic particle production process. Collect, analyze, and standardize the raw material supply data, raw material quality data, and production equipment operation data in a unified manner to generate raw material production characteristic data. Step S2: Based on the raw material production characteristic data, perform a collaborative analysis of the batching process, mixing process, and melt extrusion process in the plastic particle production process, establish production process execution status information, and generate a set of process control parameters based on the production process execution status information. Step S3: Based on the process control parameter set, dynamically adjust the temperature control unit, pressure control unit, and extrusion control unit in the plastic particle production process, and obtain the adjusted production process feedback data in real time. Perform quality correlation analysis on the production process feedback data to generate particle quality assessment results. Step S4: Based on the particle quality assessment results, comprehensively evaluate the operating status of the production equipment, the process execution status, and the product quality status, generate production optimization control instructions, and feed the production optimization control instructions back to the production process for closed-loop control to achieve continuous and stable production of plastic particles.

2. The method for controlling the production of plastic particles according to claim 1, characterized in that, Step S1 further includes: The detection devices installed in the raw material storage area, conveying area and batching area acquire batch information, type information, moisture content information, particle size information and auxiliary material addition information of plastic resin raw materials, and acquire the operating status information of conveying equipment, metering equipment and mixing equipment. All acquired data are processed synchronously according to a unified time benchmark, and the correlation between raw material data is established. A raw material production dataset is constructed based on the source of raw materials, the quality of raw materials, and the operating status of equipment. The raw material production dataset is then standardized and its features are classified to generate raw material production feature data that can characterize the composition, quality, and supply status of raw materials.

3. The method for controlling the production of plastic particles according to claim 1, characterized in that, Step S2 further includes: Based on the raw material production characteristic data, a production process matching relationship is established. A batching execution plan is generated according to the raw material type, auxiliary material composition, and target product specifications. Based on the batching execution plan, various raw materials are controlled to enter the mixing equipment for mixing. The operating status information of the mixing process is acquired in real time. Then, the raw material dispersion uniformity and melt preparation status are analyzed based on the mixing status information. Further, the melt flow status information and melt homogenization status information of the melt extrusion process are acquired. Finally, the process execution status information is established by combining the raw material production characteristic data, mixing status information, and melt status information, and a process control parameter set consisting of corresponding temperature control parameters, pressure control parameters, and extrusion speed control parameters is generated.

4. The method for controlling the production of plastic particles according to claim 1, characterized in that, Step S3 further includes: The plastic particle production equipment is dynamically controlled according to the process control parameter set. The operating status of each temperature zone of the extrusion equipment is adjusted by the heating control mechanism, the operating pressure inside the extrusion channel is adjusted by the pressure control mechanism, and the screw speed, feeding speed and traction speed are adjusted by the drive control mechanism. During the production process, temperature feedback data, pressure feedback data, flow feedback data, and melt operation feedback data are collected in real time. At the same time, particle size information, particle shape information, and uniformity information in the pelletizing process are obtained. The obtained production feedback data is correlated with product quality data to form particle quality assessment results.

5. The method for controlling the production of plastic particles according to claim 1, characterized in that, Step S4 further includes: Based on the particle quality assessment results generated in step S3, obtain the equipment operation status information, process execution status information, and product quality status information within the corresponding production cycle; Based on the particle quality assessment results, key production factors affecting product quality stability are identified, and a comprehensive production assessment result is established by combining equipment operating status, process execution status, and product quality status. Based on the comprehensive production assessment results, production optimization control instructions are generated and sent to the raw material supply link, process control link, and equipment execution link respectively. The raw material ratio, process parameters, and equipment operating parameters in the subsequent production process are dynamically optimized in real time to achieve closed-loop control of the plastic particle production process.

6. A production control system for plastic particles, characterized in that, Includes the following modules; The production data construction module is used to acquire raw material data, equipment data, and production status data generated during the production of plastic particles, and to establish a unified data resource pool to form raw material production characteristic data. The process coordination and control module is connected to the production data construction module. It is used to receive raw material production characteristic data, coordinate the batching process, mixing process, melting process and extrusion process in the production process, and generate a set of process control parameters to realize dynamic control of the production process. The production optimization management module is connected to the production data construction module and the process collaborative control module, respectively. It is used to acquire production feedback data and product quality data, comprehensively evaluate the production process, and generate production optimization control instructions to realize adaptive closed-loop control of the plastic particle production process.

7. The production control system for plastic particles according to claim 6, characterized in that, The production data construction module includes: The data construction unit is used to acquire raw material data, auxiliary material data, equipment operation data and production status data generated during the production of plastic particles, and to uniformly receive, synchronize, classify and organize and correlate the raw material data, auxiliary material data, equipment operation data and production status data to form a structured production dataset. The feature generation unit is used to establish the correlation between the raw material composition status, raw material quality status, raw material supply status and equipment operation status based on the structured production dataset, perform feature extraction and status characterization processing on the correlated data, generate raw material production feature data, and send the raw material production feature data to the process collaborative control module.

8. The production control system for plastic particles according to claim 6, characterized in that, The process coordination and control module includes: The process analysis unit is used to receive raw material production characteristic data, perform correlation analysis on batching process, mixing process and melt extrusion process, establish process execution status information, and generate a set of process control parameters including temperature control parameters, pressure control parameters, feeding control parameters, screw speed control parameters and traction speed control parameters based on the process execution status information. The process control unit is used to receive a set of process control parameters and control the operation of the batching equipment, mixing equipment, extrusion equipment and pelletizing equipment according to the set of process control parameters. It dynamically adjusts the raw material feeding process, raw material mixing process, melt extrusion process and particle forming process, and at the same time acquires temperature feedback information, pressure feedback information, flow feedback information and equipment operation feedback information during the production process.

9. The production control system for plastic particles according to claim 6, characterized in that, The production optimization management module includes: The quality decision unit is used to receive production feedback information and plastic particle quality inspection information, perform comprehensive analysis on the production feedback information and plastic particle quality inspection information, generate particle quality assessment results, and generate production optimization control instructions based on particle quality assessment results, equipment operating status information and process execution status information. The closed-loop control unit receives production optimization control commands and sends them to the production data construction module and the process coordination and control module. It dynamically corrects the raw material supply status, process execution status, and equipment operation status, while continuously receiving updated production data and feedback data. It tracks and manages the production optimization results, forming a closed-loop control system that links raw material analysis, process control, quality assessment, and optimization control, thereby achieving continuous and stable operation of the plastic particle production process.

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