A method for controlling process parameters of full-automatic mixing and production of heat-conducting silicone grease

Abstract

The present application relates to the technical field of process control, in particular to a kind of heat-conducting silicone grease full-automatic mixing and production process parameter control method, comprising the following steps: obtaining formula information and basic process parameters, set weighing, feeding, stirring, temperature control, vacuum defoaming and discharging as process, generate batch control task, collect weighing change data, stirring motor load data, kettle temperature, jacket temperature and vacuum pressure when executing batch control task, generate feeding execution parameter according to weighing increment, unit time feeding amount and target residual amount, generate mixing state determination result according to stirring motor load data and current feeding stage, calculate temperature change rate and vacuum pressure drop rate, generate process switching instruction or correction control instruction.The present application is associated by process identification, process state and execution process curve, so that feeding, stirring, temperature control, defoaming and parameter correction form batch control chain.

Description

Technical Field

[0001] This invention relates to the field of process control technology, and in particular to a fully automated method for mixing thermal grease and controlling production process parameters. Background Technology

[0002] The field of process control technology revolves around the acquisition, transmission, judgment, calculation, storage, and control activities of production equipment, process parameters, sensor signals, and actuators. Industrial computers, programmable logic controllers (PLCs), field instruments, valves, pumps, stirring motors, heaters, and human-machine interfaces work together according to formula data, timing conditions, interlocking states, and set thresholds to manage the production process. In the traditional fully automated mixing and process parameter control method for thermal grease, parameters are controlled during the metering, mixing, dispersion, temperature control, vacuum degassing, cooling transfer, and filling stages of thermal grease production, including base materials, thermally conductive fillers, and additives. Typically, weighing sensors, temperature sensors, vacuum gauges, speed detectors, torque detectors, and flow meters acquire data on weight, temperature, vacuum level, speed, load, flow rate, and batch records. The control program compares and judges based on preset formulas, sampled values, time sequence, and equipment status, and issues start / stop or adjustment commands to metering pumps, feed valves, stirring motors, vacuum pumps, heaters, and delivery pumps.

[0003] Traditional thermal grease mixing and production relies on preset formulas and fixed process sequence control for weighing, feeding, stirring, temperature control, vacuum degassing, and discharging. Weighing values, rotation speed, temperature, vacuum degree, and batch records are mostly judged based on single-point thresholds or fixed time. The quality changes during filler addition and the changes in stirring load are not sufficiently correlated. Temperature changes and vacuum pressure changes are difficult to link during process switching. Abnormal states are mostly limited to alarm records. There is insufficient relationship between process curves between batches. Adjustment of process parameters depends on on-site experience, and the control basis is scattered. Summary of the Invention

[0004] The purpose of this invention is to provide a fully automated method for mixing and controlling production process parameters of thermal conductive grease. This method integrates weighing, feeding, stirring, temperature control, vacuum degassing, discharging, and batch recording into the same process control chain during the production of thermal conductive grease. This allows feeding execution, mixing state determination, stage switching, anomaly correction, and subsequent batch parameter calls to be processed in a coordinated manner based on production process data.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a method for fully automated mixing and production process parameter control of thermal grease, comprising the following steps:

[0006] The formula information and basic process parameters of the target batch are obtained, and weighing, feeding, stirring, temperature control, vacuum degassing, and discharging are identified as continuous processes, generating a batch control task. During the execution of the batch control task, weighing change data, stirring motor load data, vessel temperature, jacket temperature, and vacuum pressure are collected synchronously, and the collection time, current process identifier, and corresponding process data are synchronously written into the current batch record.

[0007] Feeding execution parameters are generated based on the weighing increment, feed rate per unit time, and target remaining amount in the weighing change data, and output to the metering pump or feeding valve. The metering pump speed or feeding valve opening is adjusted according to the feeding execution parameters. When the target remaining amount meets a preset threshold condition, a weighing completion status is generated. The mixing state determination result is generated by comparing the stirring motor load data, the current feeding stage, stirring speed, and stirring duration according to the load change sequence. The temperature change rate and vacuum pressure drop rate are calculated. Based on the current process identifier, the weighing completion status, the mixing state determination result, and the temperature change rate or vacuum pressure drop rate are compared with the stage switching conditions corresponding to the current process. When the stage switching conditions are met, a process switching command is generated.

[0008] When weighing deviation, sudden load increase, temperature exceeding limit, or abnormal vacuum pressure meets the abnormal triggering conditions, a correction control instruction is generated according to the current process identifier. The corresponding actuator action is adjusted according to the correction control instruction. The execution process curves that have not triggered abnormalities in the current batch and the execution process curves after being processed by the correction control instruction are stored. The execution process curves are called to correct the basic process parameters when initializing subsequent batches of the same formula.

[0009] Furthermore, when obtaining the formula information and basic process parameters of the target batch, the material name, target mass, feeding sequence, and allowable deviation are read from the batch formula record, and the stirring speed, temperature control range, and vacuum control range are read from the process parameter record. The target mass, feeding sequence, allowable deviation, stirring speed, temperature control range, and vacuum control range are respectively associated with the corresponding processes in weighing, feeding, stirring, temperature control, vacuum degassing, and discharging. When the association results are complete, a batch control task is generated. When there are missing items in the association results, the generation of the batch control task is stopped and a parameter supplement prompt is output.

[0010] Furthermore, when executing the batch control task, the weighing device collects the weighing change data, the stirring motor drive feedback interface collects the stirring motor load data, the vessel temperature sensor collects the vessel temperature, the jacket temperature sensor collects the jacket temperature, and the pressure transmitter collects the vacuum pressure. The weighing change data, the stirring motor load data, the vessel temperature, the jacket temperature, and the vacuum pressure are written into the current batch record according to the collection time. When the collection time matches the current process identifier, the corresponding process data is retained. When the collection time does not match the current process identifier, it is determined to be a timing synchronization abnormality, a timestamp calibration command is generated, and the current batch record is resynchronized using the host computer's reference time.

[0011] Furthermore, when generating the feeding execution parameters based on the weighing increment, the amount of material fed per unit time, and the target remaining amount in the weighing change data, the target remaining amount is compared with a preset feeding interval; when the target remaining amount is higher than the upper limit of the preset feeding interval, a continuous feeding parameter is generated based on the amount of material fed per unit time, and the continuous feeding parameter is output to the metering pump or feeding valve; when the target remaining amount is within the preset feeding interval, an intermittent feeding parameter is generated based on the weighing increment, and the intermittent feeding parameter is output to the metering pump or feeding valve; when the target remaining amount is lower than the lower limit of the preset feeding interval, a stop feeding parameter is generated.

[0012] Furthermore, when generating the mixing state determination result based on the stirring motor load data, the current feeding stage, the stirring speed, and the stirring duration, the stirring motor load data is divided into a pre-feeding load segment, a feeding-in-process load segment, and a post-feeding load segment according to the acquisition time; the load increase amplitude is determined based on the pre-feeding load segment and the feeding-in-process load segment, and the load fluctuation duration is determined based on the feeding-in-process load segment and the post-feeding load segment; when the load increase amplitude meets the load permissible condition corresponding to the current feeding stage, and the load fluctuation duration meets the stability condition corresponding to the stirring duration, a mixing-in-place state is generated; when the load increase amplitude does not meet the load permissible condition, or the load fluctuation duration does not meet the stability condition, a continued stirring state or a reduced-speed stirring state is generated.

[0013] Further, after calculating the temperature change rate and the vacuum pressure decrease rate, the stage switching conditions corresponding to the current process are divided into temperature control stage switching conditions and vacuum degassing stage switching conditions. When the temperature change rate is within the allowable change range of the temperature control stage, and the difference between the temperature inside the vessel and the jacket temperature meets the temperature control stage difference condition, a temperature control stage completion state is generated. When the vacuum pressure decrease rate meets the vacuum degassing stage pressure reduction condition, and the vacuum pressure meets the vacuum degassing stage maintenance condition, a vacuum degassing stage completion state is generated. When the temperature control stage completion state or the vacuum degassing stage completion state matches the current process, the process switching instruction is generated.

[0014] Furthermore, when the weighing deviation, sudden load increase, temperature exceeding the limit, or abnormal vacuum pressure meets the abnormality triggering conditions, the abnormality type is matched with the current process identifier; when the abnormality type corresponds to the weighing or feeding process, a material replenishment control command or a material feeding pause control command is generated; when the abnormality type corresponds to the stirring process, a speed-reducing stirring control command is generated; when the abnormality type corresponds to the temperature control or vacuum degassing process, a temperature control correction control command or a re-degassing control command is generated; the material replenishment control command, the material feeding pause control command, the speed-reducing stirring control command, the temperature control correction control command, or the re-degassing control command is used as the correction control command.

[0015] Furthermore, when storing the execution process curve for the current batch, the weighing change data, the stirring motor load data, the vessel temperature, the jacket temperature, the vacuum pressure, the process switching command, and the correction control command are associated and stored according to the current process identifier to form a historical feature curve library; when initializing subsequent batches of the same formula, the formula information of the subsequent batch is matched with the formula information of the stored batch; when the material name, feeding sequence, and target quality meet the matching conditions of the same formula, the corresponding execution process curve is called; the stirring speed, temperature control range, or vacuum control range in the basic process parameters are corrected according to the called execution process curve.

[0016] Furthermore, when correcting the basic process parameters based on the invoked execution process curve, the feeding duration, stirring motor load variation range, in-vessel temperature variation range, and vacuum pressure variation range in the execution process curve are extracted as historical operating envelopes. The feeding duration is compared with the preset feeding process duration of subsequent batches, the stirring motor load variation range is compared with the stirring motor load threshold of subsequent batches, the in-vessel temperature variation range is compared with the temperature control range of subsequent batches, and the vacuum pressure variation range is compared with the vacuum control range of subsequent batches. When the deviation of the comparison result falls within the preset parameter correction range, the upper or lower limit of the stirring speed, temperature control range, or vacuum control range is corrected according to the extreme value range of the historical operating envelope.

[0017] Furthermore, during the initialization of subsequent batches of the same formula, if the formula information of the subsequent batch does not meet the matching conditions of the same formula with the formula information of the stored batch, the corresponding execution process curve is prohibited from being called; the basic process parameters of the subsequent batch are used as the current initialization parameters, and the material name, feeding order or target quality that does not meet the matching conditions of the same formula are written into the current batch record.

[0018] Compared with the prior art, the advantages and positive effects of the present invention are as follows:

[0019] In this invention, by transforming the formula information and basic process parameters of the target batch into batch control tasks, weighing, feeding, stirring, temperature control, vacuum degassing, and discharging can be continuously recorded under the same process identifier. Weighing increment, feeding amount per unit time, and target remaining amount jointly generate feeding execution parameters, ensuring that the actions of the metering pump or feeding valve correspond to the feeding state. Stirring motor load data, temperature change rate, and vacuum pressure drop rate are used in stage switching comparisons, shifting the process progression from a fixed time frame to a process state. After anomaly triggering conditions are associated with the current process identifier, corrective control commands can correspond to the weighing, feeding, stirring, temperature control, and degassing stages. The execution process curve provides data for parameter correction in subsequent batches of the same formula. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the accompanying drawings without creative effort.

[0021] Figure 1 This is the main flowchart of batch control for the fully automated mixing and production process parameter control method of thermal grease of the present invention;

[0022] Figure 2 This is a flowchart of the batch control task filing and timing synchronization process of the present invention;

[0023] Figure 3 This is a data flow diagram of the feeding execution parameters and mixing state determination of the present invention;

[0024] Figure 4 This is a closed-loop diagram of the phase switching and anomaly correction feedback in this invention;

[0025] Figure 5 This is a logic diagram for the execution process curve calling and basic process parameter correction of the present invention. Detailed Implementation

[0026] The embodiments of the present invention will be described below with reference to the technical solutions and accompanying drawings described herein. The fully automated mixing and production process parameter control method for thermal conductive silicone grease described in the scope of protection text takes batch production processes as the processing object, involving technical objects such as formula information, basic process parameters, batch control tasks, weighing change data, stirring motor load data, reactor temperature, jacket temperature, vacuum pressure, mixing state determination results, process switching instructions, correction control instructions, and execution process curves. In the following embodiments, weighing, feeding, stirring, temperature control, vacuum degassing, and discharging are described as continuous processes, and the weighing device, stirring motor drive feedback interface, reactor temperature sensor, jacket temperature sensor, pressure transmitter, metering pump, or feeding valve are described as data sources or execution objects. Figure 1 Used to illustrate the overall control process. Figures 2 to 5 These are respectively used to explain batch task filing and timing synchronization, material feeding and mixing status determination, stage switching and anomaly correction, execution process curve calling and parameter correction.

[0027] Please see Figures 1 to 5 This embodiment provides a fully automated method for mixing and controlling production process parameters of thermal conductive silicone grease. This method is used for process control in a batch mixing production line for thermal conductive silicone grease. Before executing a target batch, the production line reads the batch formula record and process parameter record. During batch operation, it collects weighing change data, stirring motor load data, reactor temperature, jacket temperature, and vacuum pressure. Based on the process status of different steps, it generates feeding execution parameters, mixing state judgment results, process switching instructions, and correction control instructions. This method does not use a single fixed duration or a single threshold as the basis for all process progression. Instead, it synchronously writes the current process identifier and process data into the current batch record, forming a continuous data and control chain for weighing, feeding, stirring, temperature control, vacuum degassing, discharging, and initialization of subsequent batches of the same formula.

[0028] S1: Obtain the formula information and basic process parameters of the target batch, and determine weighing, feeding, stirring, temperature control, vacuum degassing and discharging as continuous processes to generate batch control tasks.

[0029] In S1, the formula information for the target batch is obtained from the batch formula record, which at least records the material name, target mass, feeding sequence, and allowable deviation. Basic process parameters are obtained from the process parameter record, which at least records the stirring speed, temperature control range, and vacuum control range. After reading the formula information and basic process parameters, the target mass is associated with the weighing and feeding processes, the feeding sequence is associated with the feeding process, the allowable deviation is associated with the weighing and feeding processes, the stirring speed is associated with the stirring process, the temperature control range is associated with the temperature control process, the vacuum control range is associated with the vacuum degassing process, and a sequential relationship is established between the discharge process and the completion status of the aforementioned processes.

[0030] S1 also performs a completeness check on the association results. Complete association results mean that the material name, target mass, feeding sequence, allowable deviation, stirring speed, temperature control range, and vacuum control range can all correspond to at least one of the following processes: weighing, feeding, stirring, temperature control, vacuum degassing, and discharging, and that the same target batch has a unique batch identifier. When the association results are complete, a batch control task is generated based on the consecutive processes and corresponding parameters. Missing association results mean that any consecutive process lacks a necessary formula or process field, or that inconsistent material names, feeding sequences, or target masses exist under the same batch identifier. When missing association results exist, batch control task generation stops, and a parameter supplementation prompt is output. The parameter supplementation prompt is written to the current batch record, enabling subsequent supplementation operations to locate the missing fields and corresponding processes.

[0031] The output of S1 is a batch control task, which is used to constrain subsequent data acquisition, feeding control, mixing state determination, stage switching, anomaly correction, and execution process curve storage. In the batch control task, weighing, feeding, stirring, temperature control, vacuum degassing, and discharging are arranged in consecutive steps, and the current step identifier is updated as the steps progress. The current step identifier serves as a common index for subsequent process data writing, anomaly type matching, and execution process curve association storage.

[0032] S2, during the execution of batch control tasks, synchronously collects weighing change data, stirring motor load data, vessel temperature, jacket temperature and vacuum pressure, and synchronously writes the collection time, current process identifier and corresponding process data into the current batch record.

[0033] In S2, weighing change data is collected by the weighing device, reflecting the change in weighing values ​​before and after feeding. Agitator motor load data is collected by the agitator motor drive feedback interface, reflecting the load changes of the agitator motor before, during, and after feeding. The vessel temperature and jacket temperature are collected by the vessel temperature sensor and jacket temperature sensor, respectively, and the vacuum pressure is collected by the pressure transmitter. Each time data is collected, the collection time and the current process identifier are written into the current batch record, ensuring that each set of process data has both a time source and a process source.

[0034] In S2, the current batch record uses the batch identifier as the record entry point and the current process identifier as the segment index. After weighing change data, stirring motor load data, vessel temperature, jacket temperature, and vacuum pressure are written into the current batch record according to the acquisition time, a time synchronization judgment is first performed. When the acquisition time matches the current process identifier, the corresponding process data is retained and allowed to enter subsequent feeding control, mixing state judgment, temperature change rate calculation, or vacuum pressure drop rate calculation. When the acquisition time does not match the current process identifier, the corresponding process data is judged as a time synchronization anomaly, a timestamp calibration instruction is generated, and the current batch record is resynchronized using the host computer's reference time. After resynchronization, the process data is rewritten under the corresponding current process identifier according to the calibrated acquisition time; process data that has not been synchronized does not enter the subsequent judgment chain.

[0035] The timing synchronization in S2 does not change the physical source of the process data itself, but rather calibrates the correspondence between the process data and the current process identifier. The weighing device, stirring motor drive feedback interface, vessel temperature sensor, jacket temperature sensor, and pressure transmitter serve as the main data acquisition components, the current batch record serves as the process data receiving location, and the host computer's reference time serves as the basis for time calibration. Through this process, the weighing change data, stirring motor load data, vessel temperature, jacket temperature, and vacuum pressure used in subsequent steps can all be traced back to the corresponding acquisition time and process segment.

[0036] S3 generates feeding execution parameters based on the weighing increment, feeding amount per unit time, and target remaining amount in the weighing change data, and outputs them to the metering pump or feeding valve. The metering pump speed or feeding valve opening is adjusted according to the feeding execution parameters. The mixing state determination result is generated by comparing the mixing motor load data, the current feeding stage, the mixing speed, and the mixing duration according to the load change sequence.

[0037] In S3, the weighing increment is determined by the weighing change data corresponding to adjacent acquisition times, the feed rate per unit time is determined by the weighing increment and the corresponding acquisition time interval, and the target remaining amount is determined by the difference between the target mass and the current weighing value. When generating feed execution parameters, the target remaining amount is first compared with the preset feeding interval. When the target remaining amount is higher than the upper limit of the preset feeding interval, continuous feeding parameters are generated based on the feed rate per unit time and output to the metering pump or feeding valve, causing the metering pump speed or feeding valve opening to operate according to the continuous feeding parameters. When the target remaining amount is within the preset feeding interval, intermittent feeding parameters are generated based on the weighing increment and output to the metering pump or feeding valve, causing the metering pump or feeding valve to perform feeding according to the intermittent feeding parameters. When the target remaining amount is lower than the lower limit of the preset feeding interval, stop feeding parameters are generated, causing the metering pump or feeding valve to stop feeding.

[0038] In S3, continuous feeding parameters, intermittent feeding parameters, and stop feeding parameters are all different output states of the feeding execution parameters. Continuous feeding parameters are used when the target remaining amount is not close to the feeding interval; intermittent feeding parameters are used when the target remaining amount enters the feeding interval; and stop feeding parameters are used when the target remaining amount is below the lower limit of the feeding interval. These three output states are mutually exclusive; only the feeding execution parameter corresponding to the comparison result with the target remaining amount is retained at the same acquisition time. After the feeding execution parameters are output, the metering pump speed or feeding valve opening is used as the execution quantity receiving control, and the weighing change data is used as the feedback input for the next round of feeding control, forming a closed path of weighing input, feeding parameter generation, actuator action, and weighing feedback. Simultaneously, when the target remaining amount meets the preset threshold condition, a weighing completion status is generated and written to the current batch record.

[0039] In S3, the mixing state determination result is generated jointly by the agitator motor load data, the current feeding stage, the agitator speed, and the agitator duration. The agitator motor load data is divided into three segments according to the acquisition time: the load segment before feeding, the load segment during feeding, and the load segment after feeding. The load increase amplitude is determined based on the load segments before and during feeding, and the load fluctuation duration is determined based on the load segments during and after feeding. The load increase amplitude characterizes the impact of the feeding process on the agitator motor load, and the load fluctuation duration characterizes the time required for the load to stabilize after feeding.

[0040] In S3, the current feeding stage corresponds to the load permissible condition, and the stirring duration corresponds to the stability condition. When the load increase meets the load permissible condition corresponding to the current feeding stage, and the load fluctuation duration meets the stability condition corresponding to the stirring duration, a mixing-in-place state is generated. When the load increase does not meet the load permissible condition, or the load fluctuation duration does not meet the stability condition, a continue stirring state or a slow-down stirring state is generated. The continue stirring state is used to maintain the current stirring process, and the slow-down stirring state is used to change the stirring execution state when the load change exceeds the corresponding permissible condition. The mixing state determination result is written to the current batch record and used as input for subsequent stage switching judgments.

[0041] S4. Calculate the temperature change rate and vacuum pressure drop rate. Based on the current process identifier, compare the weighing completion status, mixing status determination result, temperature change rate or vacuum pressure drop rate with the stage switching conditions corresponding to the current process. When the stage switching conditions are met, generate a process switching instruction.

[0042] In S4, the temperature change rate is determined based on the in-vessel temperature and sampling time under the same current process identifier, and the vacuum pressure drop rate is determined based on the vacuum pressure and sampling time under the same current process identifier. Stage switching conditions are divided into weighing stage switching conditions, mixing stage switching conditions, temperature control stage switching conditions, and vacuum degassing stage switching conditions according to the current process. The weighing completion status is derived from the comparison result between the weighing change data and the target mass in S3; the mixing status determination result is derived from the load change time sequence comparison result in S3; the temperature change rate is derived from the change in in-vessel temperature over sampling time; and the vacuum pressure drop rate is derived from the change in vacuum pressure over sampling time.

[0043] In S4, when the temperature change rate is within the allowable range of the temperature control stage, and the difference between the vessel temperature and the jacket temperature meets the temperature control stage difference condition, a temperature control stage completion status is generated. If the temperature control stage completion status matches the current process, a corresponding process switching instruction can be generated. If the temperature control stage completion status does not match the current process, the current process does not proceed, and the vessel temperature and jacket temperature continue to be collected until a new temperature change rate and difference condition are met for the next round of comparison.

[0044] In S4, when the vacuum pressure decrease rate meets the pressure reduction condition of the vacuum degassing stage and the vacuum pressure meets the maintenance condition of the vacuum degassing stage, a vacuum degassing stage completion status is generated. When the vacuum degassing stage completion status matches the current process, a corresponding process switching instruction can be generated. When the vacuum degassing stage completion status does not match the current process, the current process does not proceed and continues to collect vacuum pressure until a new vacuum pressure decrease rate and vacuum pressure status enter the next round of comparison.

[0045] In S4, process switching instructions are not generated directly from a single acquired value. Instead, they are generated based on the current process identifier, after the corresponding weighing completion status, mixing state determination result, temperature change rate, or vacuum pressure drop rate meet the stage switching conditions corresponding to the current process. The process switching instruction is written to the current batch record and used to update the current process identifier of the batch control task. After the current process identifier is updated, subsequent acquisition times, process data, and execution instructions are all recorded under the new current process identifier.

[0046] S5. When weighing deviation, sudden load increase, temperature exceeding the limit, or abnormal vacuum pressure meets the abnormal triggering conditions, a correction control instruction is generated according to the current process identifier. The corresponding actuator action is adjusted according to the correction control instruction. The execution process curves that have not triggered abnormalities in the current batch and the execution process curves after being processed by the correction control instruction are stored. The execution process curves are called to correct the basic process parameters when the batch of the same formula is initialized in the future.

[0047] In S5, the abnormal triggering conditions correspond to weighing deviation, sudden load increase, temperature exceeding limits, and vacuum pressure abnormality, respectively. Weighing deviation is determined by comparing the weighing change data with the target mass or allowable deviation; sudden load increase is determined by comparing the stirring motor load data with the allowable load conditions corresponding to the current feeding stage; temperature exceeding limits is determined by comparing the vessel temperature, jacket temperature, or temperature change rate with the temperature control range; and vacuum pressure abnormality is determined by comparing the vacuum pressure or vacuum pressure decrease rate with the vacuum control range. When any abnormality meets the corresponding abnormal triggering condition, the abnormality type is matched with the current process identifier.

[0048] In S5, when the anomaly type corresponds to the weighing or feeding process, a replenishment control command or a pause feeding control command is generated. The replenishment control command is used to initiate the replenishment action of the metering pump or feeding valve, while the pause feeding control command is used to stop the feeding action of the metering pump or feeding valve. When the anomaly type corresponds to the mixing process, a speed-reducing mixing control command is generated, causing the mixing motor to operate in a speed-reducing mixing state. When the anomaly type corresponds to the temperature control or vacuum degassing process, a temperature control correction control command or a re-degassing control command is generated. The temperature control correction control command is used to adjust the temperature control execution state, while the re-degassing control command is used to re-enter the corresponding pressure control process of the vacuum degassing process. All replenishment control commands, pause feeding control commands, speed-reducing mixing control commands, temperature control correction control commands, and re-degassing control commands are written as correction control commands to the current batch record.

[0049] In S5, the execution process curve for the current batch is formed by associating weighing change data, stirring motor load data, vessel temperature, jacket temperature, vacuum pressure, process switching instructions, and correction control instructions according to the current process identifier. When storing the execution process curve for the current batch, the above process data and control instructions are written into the historical characteristic curve library. The historical characteristic curve library organizes its storage content according to batch identifier, formula information, and current process identifier. Execution process curves that have not triggered anomalies and execution process curves processed by correction control instructions retain their corresponding process sources and processing states, enabling subsequent batches of the same formula to distinguish between normal process states and corrected process states.

[0050] In S5, during the initialization of subsequent batches of the same formula, the formula information of the subsequent batches is matched with the formula information of the stored batches. When the material name, feeding sequence, and target quality meet the matching conditions of the same formula, the corresponding execution process curve is invoked. When correcting the basic process parameters based on the invoked execution process curve, the feeding duration, stirring motor load variation range, in-vessel temperature variation range, and vacuum pressure variation range in the execution process curve are extracted as historical operating envelopes. The feeding duration is compared with the preset feeding process duration of subsequent batches, the stirring motor load variation range is compared with the stirring motor load threshold of subsequent batches, the in-vessel temperature variation range is compared with the temperature control range of subsequent batches, and the vacuum pressure variation range is compared with the vacuum control range of subsequent batches.

[0051] In S5, when the deviation of the comparison result falls within the preset parameter correction range, the upper or lower limit values ​​of the stirring speed, temperature control range, or vacuum control range are corrected according to the extreme value range of the historical operating envelope. The deviation amount is used to indicate the degree of deviation between the preset process state of subsequent batches and the historical operating envelope, and the preset parameter correction range is used to limit the boundary that allows correction using the historical operating envelope. If the formula information of subsequent batches does not meet the matching conditions of similar formulas with the formula information of stored batches, the corresponding execution process curve is prohibited from being called, the basic process parameters of subsequent batches are used as the current initialization parameters, and the material names, feeding sequences, or target qualities that do not meet the matching conditions of similar formulas are written into the current batch record.

[0052] Through steps S1 to S5, a complete chain is formed for the target batch, from reading the formula information to correcting the basic process parameters. The batch control task provides identifiers for consecutive processes and the current process; process data acquisition provides inputs for weighing, load, temperature, and pressure; feeding execution parameters and mixing state determination results provide the control basis for the feeding and stirring stages; temperature change rate and vacuum pressure drop rate provide the basis for stage switching; correction control commands provide the basis for adjusting the actuators under abnormal conditions; and the execution process curve provides the basis for parameter correction for subsequent batches of the same formula. The input sources, processing rules, intermediate states, output results, and subsequent call locations in each of the above steps can all be traced in the current batch record or the historical characteristic curve library.

[0053] The above embodiments are only used to illustrate the implementable process of the present invention. The technical objects, data objects, state objects, processing order, and control relationships recorded in the protection scope text and invention content jointly define the technical boundary of the present invention. Terms such as formula information, basic process parameters, batch control tasks, weighing change data, stirring motor load data, kettle temperature, jacket temperature, vacuum pressure, feeding execution parameters, mixing state determination results, process switching instructions, correction control instructions, execution process curves, and historical characteristic curve libraries used in the embodiments, without departing from the scope of the technical solution supported by the present invention, can be replaced, modified, combined, ordered, or have their field names changed or their execution subjects or carrier forms changed by those skilled in the art. All such replacements, modifications, combinations, order adjustments, field name transformations, execution subject transformations, or carrier form transformations should fall within the scope of protection of this patent, but should not be extended to topics or objects not supported by the technical solution recorded in the application documents.

Claims

1. A fully automated method for mixing and controlling production process parameters of thermal conductive silicone grease, characterized in that, Obtain the formula information and basic process parameters of the target batch, and determine weighing, feeding, stirring, temperature control, vacuum degassing and discharging as continuous processes to generate batch control tasks; During the execution of the batch control task, weighing change data, stirring motor load data, vessel temperature, jacket temperature and vacuum pressure are collected in real time, and the collection time, current process identifier and corresponding process data are synchronously written into the current batch record. Feeding execution parameters are generated based on the weighing increment, feed amount per unit time, and target remaining amount in the weighing change data, and output to the metering pump or feeding valve. The metering pump speed or feeding valve opening is adjusted according to the feeding execution parameters. When the target remaining amount meets the preset threshold condition, a weighing completion state is generated. The mixing state determination result is generated by comparing the stirring motor load data, the current feeding stage, stirring speed, and stirring duration according to the load change sequence. Calculate the temperature change rate and vacuum pressure drop rate. Based on the current process identifier, compare the weighing completion status, the mixing status determination result, the temperature change rate or vacuum pressure drop rate with the stage switching conditions corresponding to the current process. When the stage switching conditions are met, generate a process switching instruction. When weighing deviation, sudden load increase, temperature exceeding limit, or abnormal vacuum pressure meets the abnormality triggering conditions, a correction control instruction is generated according to the current process identifier. The corresponding actuator action is adjusted according to the correction control instruction. The execution process curves that have not triggered abnormalities in the current batch and the execution process curves after being processed by the correction control instruction are stored. The execution process curves are called to correct the basic process parameters when initializing subsequent batches of the same formula.

2. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 1, characterized in that, When obtaining the formula information and basic process parameters of the target batch, the material name, target mass, feeding sequence and allowable deviation are read from the batch formula record, and the stirring speed, temperature control range and vacuum control range are read from the process parameter record. The target mass, the feeding sequence, the allowable deviation, the stirring speed, the temperature control range, and the vacuum control range are respectively associated with the corresponding processes in weighing, feeding, stirring, temperature control, vacuum degassing, and discharging. When the association results are complete, a batch control task is generated. When there are missing items in the association results, the generation of the batch control task is stopped and a parameter supplementation prompt is output.

3. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 1, characterized in that, When performing the batch control task, the weighing device collects the weighing change data, the stirring motor drive feedback interface collects the stirring motor load data, the in-vessel temperature sensor collects the in-vessel temperature, the jacket temperature sensor collects the jacket temperature, and the pressure transmitter collects the vacuum pressure. The weighing change data, the stirring motor load data, the vessel temperature, the jacket temperature, and the vacuum pressure are written into the current batch record according to the acquisition time. When the acquisition time matches the current process identifier, the corresponding process data is retained. When the acquisition time does not match the current process identifier, it is determined to be a timing synchronization abnormality, a timestamp calibration instruction is generated, and the current batch records are resynchronized using the host computer's reference time.

4. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 1, characterized in that, When generating the feeding execution parameters based on the weighing increment, the amount of material fed per unit time, and the target remaining amount in the weighing change data, the target remaining amount is compared with a preset feeding interval. When the target remaining amount is higher than the upper limit of the preset replenishment range, a continuous feeding parameter is generated based on the feeding amount per unit time, and the continuous feeding parameter is output to the metering pump or feeding valve. When the target remaining amount is within the preset replenishment range, intermittent replenishment parameters are generated based on the weighing increment, and the intermittent replenishment parameters are output to the metering pump or feeding valve; When the target remaining amount is lower than the lower limit of the preset replenishment range, a stop feeding parameter is generated.

5. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 1, characterized in that, When generating the mixing state determination result based on the stirring motor load data, the current feeding stage, the stirring speed and stirring duration, the stirring motor load data is divided into the pre-feeding load segment, the feeding load segment and the post-feeding load segment according to the collection time. The load increase rate is determined based on the load segment before feeding and the load segment during feeding, and the duration of load fluctuation is determined based on the load segment during feeding and the load segment after feeding. When the load increase meets the load allowable condition corresponding to the current feeding stage, and the load fluctuation duration meets the stability condition corresponding to the stirring duration, a mixing in place state is generated. When the load increase does not meet the load allowable condition, or the load fluctuation duration does not meet the stability condition, a continued stirring state or a reduced stirring state is generated.

6. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 1, characterized in that, After calculating the temperature change rate and the vacuum pressure drop rate, the stage switching conditions corresponding to the current process are divided into temperature control stage switching conditions and vacuum degassing stage switching conditions. When the temperature change rate is within the allowable range of the temperature control stage, and the difference between the temperature inside the vessel and the temperature in the jacket meets the difference condition of the temperature control stage, the temperature control stage is completed. When the vacuum pressure decrease rate meets the pressure reduction condition of the vacuum degassing stage and the vacuum pressure meets the maintenance condition of the vacuum degassing stage, the vacuum degassing stage is completed. When the completion status of the temperature control stage or the completion status of the vacuum degassing stage matches the current process, the process switching instruction is generated.

7. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 1, characterized in that, When the weighing deviation, the sudden increase in load, the temperature exceeding the limit, or the abnormal vacuum pressure meets the abnormality triggering conditions, the abnormality type will be matched with the current process identifier. When the abnormality type corresponds to the weighing or feeding process, a material replenishment control command or a material feeding pause control command is generated. When the abnormality type corresponds to the stirring process, a speed-reducing stirring control command is generated; When the abnormality type corresponds to a temperature control or vacuum degassing process, a temperature control correction control command or a re-degassing control command is generated. The feeding control command, the pause feeding control command, the speed reduction stirring control command, the temperature control correction control command, or the re-defoaming control command are used as the correction control command.

8. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 1, characterized in that, When storing the execution process curves for the current batch, the weighing change data, the stirring motor load data, the vessel temperature, the jacket temperature, the vacuum pressure, the process switching command, and the correction control command are associated and stored according to the current process identifier to form a historical feature curve library; When initializing subsequent batches of the same formula, the formula information of the subsequent batches will be matched with the formula information of the stored batches. When the material name, feeding sequence, and target quality meet the matching conditions of similar formulas, the corresponding execution process curve is invoked. The stirring speed, temperature control range, or vacuum control range in the basic process parameters are corrected based on the execution process curve being invoked.

9. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 8, characterized in that, When correcting the basic process parameters based on the execution process curve that is invoked, the feeding duration, stirring motor load variation range, in-vessel temperature variation range, and vacuum pressure variation range in the execution process curve are extracted as historical operating envelopes. The feeding duration is compared with the preset feeding time of subsequent batches, the stirring motor load variation range is compared with the stirring motor load threshold of subsequent batches, the in-cabin temperature variation range is compared with the temperature control range of subsequent batches, and the vacuum pressure variation range is compared with the vacuum control range of subsequent batches. When the deviation of the comparison result falls within the preset parameter correction range, the upper or lower limit of the stirring speed, temperature control range or vacuum control range is corrected according to the extreme value range of the historical operating envelope.

10. The fully automated mixing and production process parameter control method for thermal conductive silicone grease according to claim 8, characterized in that, When initializing subsequent batches of the same type of formula, if the formula information of the subsequent batch does not meet the matching condition of the same type of formula with the formula information of the stored batch, the corresponding execution process curve shall be prohibited from being called. The basic process parameters of subsequent batches are used as the current initialization parameters, and the names, feeding order or target quality of materials that do not meet the matching conditions of the same type of formula are written into the current batch record.

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