A low-carbon production method for improving material utilization of a cable manufacturing process

Abstract

The application discloses a kind of cable manufacturing process material utilization rate promotion low-carbon production method, comprising: establishing material pedigree section, actual material input, theoretical material requirement and quality detection result are associated;According to closed loop invisible time, quality parameter fluctuation and variation trend determine conservative quality remaining margin, identify stable material redundancy;Combining local process response and subsequent compensation ability of equipment to build recoverable redundancy release domain;In the release domain, implement phased material release, and decide to continue release or parameter recovery according to actual quality result of corresponding material pedigree section;Quality verification qualified section confirms actual low-carbon benefit, and uses subsequent release domain to be modified by failure release state.The application can reduce unnecessary material input under the condition of meeting the quality requirements of cable, improve material utilization rate and the reliability of low-carbon production control.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing process control technology, and more specifically, to a low-carbon production method for improving material utilization in the cable manufacturing process. Background Technology

[0002] During the continuous extrusion process of cable insulation or sheath layers, a certain safety margin for materials is usually reserved in the production parameters to avoid quality problems such as insufficient thickness and outer diameter deviation. In actual production, even after the equipment has entered a stable operating state, this margin is often maintained at a fixed value, which can easily lead to the metered feed rate being higher than the amount of material actually required to form the product for a long time. Existing material statistics are mostly calculated on a unit basis of whole reels or batches of products, which can reflect the final material consumption, but it is difficult to accurately correspond the material at the feeding end with the specific cable sections formed subsequently and the quality inspection results.

[0003] On the other hand, after the insulation or sheathing material enters the extruder from the metering point, it still needs to undergo material retention, die extrusion, conveying, and online detection processes. There is a time lag between parameter adjustments and actual quality results. If the feed rate is directly reduced based solely on the current thickness, outer diameter, or overfeeding situation, multiple affected sections may have already occurred before new quality detection results appear. Therefore, how to combine material flow relationships, quality feedback lag, and equipment subsequent compensation capabilities to determine whether material redundancy has safe release conditions, and reduce unnecessary material input while ensuring product quality, remains a problem that needs further resolution in the low-carbon production process of cables. Summary of the Invention

[0004] A low-carbon production method for improving material utilization in cable manufacturing includes: S1. Establish a material spectrum section during the continuous extrusion process of cable insulation or sheath layer, and correlate the actual material input, theoretical material demand and quality test results to determine the material input residual. S2. Determine the closed-loop invisible time between the change of control parameters and the acquisition of the corresponding quality test results. Combine the fluctuation and trend of quality parameters to determine the conservative quality margin and identify the redundancy of stable materials. S3. Construct a recoverable redundancy release domain based on the local process response, closed-loop invisible time, and subsequent compensability of the equipment in the verified material spectrum segment. S4. Generate candidate material reduction parameter schemes within the recoverable redundancy release domain, implement phased material release for the selected candidate material reduction parameter schemes, and determine whether to continue material release or restore to the most recently verified parameters based on the actual quality test results of the corresponding material spectrum segment. S5. Confirm the actual low-carbon benefits of material spectrum segments that have passed quality verification, and shrink the subsequent recoverable redundant release domains based on the failure release status.

[0005] Specifically, S1 includes: Collect and measure feed rate, extruder screw speed, die head pressure, melt temperature, traction speed, production line speed, online thickness of insulation or sheath layer and outer diameter of finished product, and establish new production section boundaries when the production line starts or stops, changes discs, switches material batches, or when the screw speed or traction speed changes continuously beyond the stable fluctuation range. The material fed into the extruder is assigned a material spectrum segment number, and the time when the corresponding material starts to be output from the die head is determined based on the equivalent material retention between the metering feed position and the die head outlet. After the corresponding material is output from the machine head, the material movement length is accumulated according to the real-time speed of the production line. When the accumulated material movement length reaches the actual path distance between the machine head outlet and the quality inspection device, the corresponding quality inspection data is assigned to the corresponding material spectrum segment. The theoretical material requirement is determined based on the target outer diameter, target inner diameter, material density, effective length of material spectrum segment, and material process correction coefficient. The actual material input is determined based on the metering and feeding results. The material input residual is determined based on the degree of deviation between the actual material input and the theoretical material requirement.

[0006] Specifically, S2 includes: Obtain the minimum thickness, average thickness, and finished product outer diameter of the insulation or sheath layer as key quality parameters; The material residence time inside the extruder, the conveying time of the material from the die head to the quality inspection position, and the inspection time window required to form a stable quality inspection result are collectively defined as the closed-loop invisible time. For critical quality parameters with lower limit requirements, the conservative remaining margin of the corresponding critical quality parameter is determined by deducting the margin occupied by the quality parameter fluctuation, change slope, closed-loop invisible time and fluctuation protection coefficient, based on the distance between the segment mean of the corresponding critical quality parameter and the allowable lower limit. For critical quality parameters with upper limit requirements, the conservative remaining margin of the corresponding critical quality parameter is determined by deducting the margin occupied by the quality parameter fluctuation, change slope, closed-loop invisible time and fluctuation protection coefficient, based on the distance between the allowable upper limit and the segment mean of the corresponding critical quality parameter. The minimum value among the conservative margins of each key quality parameter is determined as the conservative mass margin of the corresponding material spectrum segment.

[0007] Specifically, The process fluctuation value is determined based on the fluctuation amplitude and slope of key quality parameters within the continuous material spectrum segment; When the residual of material delivery in several consecutive material spectrum segments is continuously higher than the residual identification threshold, the conservative quality margin is higher than the quality protection line, and the process fluctuation value is lower than the process fluctuation threshold, the material portion that exceeds the theoretical material demand is identified as stable material redundancy. If any of the above conditions are not met, the corresponding over-feed portion of material will be determined as a protective material margin, and automatic release of the protective material margin will be prohibited. The residual identification threshold, quality protection line, fluctuation protection coefficient, and process fluctuation threshold are determined based on verification data of cables of the same specification under stable and qualified production conditions, and are recalibrated when the material type, mold, or quality inspection location changes.

[0008] Specifically, S3 includes: From the verified material spectrum segments of cable product specifications corresponding to the current material spectrum segment, extract the correspondence between the change in control parameters and the change in material input to establish a local material response relationship, and extract the correspondence between the change in control parameters and the changes in the minimum thickness, average thickness and outer diameter of the insulation or sheath layer to establish a local quality response matrix. The adjustable control parameter vector is composed of parameters that can be adjusted online by the equipment, including screw speed, traction speed, and metering feed control. The mass change corresponding to the increment of candidate parameters is predicted based on the local mass response matrix, and the prediction uncertainty protection amount is determined based on the mass fluctuation amount. Candidate parameter increments that do not exceed the quality allowable boundary after deducting the prediction uncertainty protection amount, do not cross the quality allowable boundary during the closed-loop invisible time, and have subsequent compensation parameters that can enable the corresponding key quality parameters to return to the quality protection line within the recovery observation section are identified as recoverable material reduction parameters. The recoverable material reduction parameters that can reduce material input are combined into a recoverable redundancy release domain.

[0009] Specifically, Based on the verified adjacent material spectrum segments, the local quality response matrix and local material response vector are obtained by the local least squares method with regularization term. The local material response vector is used to characterize the local response relationship between changes in control parameters and changes in material input. The number of observation segments to be restored is determined based on the closed-loop invisible time and the average duration of the material spectrum segment. Within the recovery observation section, a set of subsequent executable compensation parameters is formed by combining the allowable range of each control parameter, the maximum single adjustment amount, and the adjustment rate limit. When the number of effective local samples is insufficient to form a reliable local quality response matrix, or when the condition number of the local quality response matrix exceeds the upper limit of stable computation, the recoverable redundancy release domain is not expanded, and the most recently verified conservative release domain is adopted. If no validated conservative release domain exists, maintain the current process parameters.

[0010] Specifically, S4 includes: Generate candidate reduction parameter schemes within the recoverable redundancy release domain; The expected reduction in material mass corresponding to each candidate material reduction parameter scheme is determined based on the local material response relationship. The provisional low-carbon benefits are determined based on the expected reduction in material mass, the carbon emission factor per unit mass of material, the incremental power consumption and the carbon emission factor of electricity corresponding to the candidate material reduction parameter scheme. From the candidate fuel reduction parameter schemes with tentatively positive low-carbon benefits, the candidate fuel reduction parameter schemes are ranked according to the predicted mass margin and the magnitude of parameter changes, and the target release scheme is determined. The first-stage detection release amount is determined based on the minimum stable adjustment amount of the equipment, the conservative mass margin, and the prediction uncertainty, and the materials for performing the first-stage material release are assigned independent material family labels. According to the material genealogy progression relationship, the materials released in the first stage are tracked to the quality inspection location, and the actual quality inspection results of the corresponding cable sections are obtained; When the actual material input decreases in the predicted direction, the conservative quality margin is not lower than the quality protection line, the process fluctuation value is not higher than the process fluctuation threshold, and the deviation between the actual quality change and the predicted result of the local quality response matrix does not exceed the model verification threshold, the next stage of material release will continue. If any of the above conditions are not met, the material release will be stopped and the parameters will be restored to the most recent verified parameters before the first stage of material release.

[0011] Specifically, S5 includes: The verified stable section under the same product specifications, same material type and similar production speed conditions most recently before material release is used as the reference state, and the actual material input per unit length of the reference state is converted to the production length of the current material spectrum section. For material spectrum segments that have passed the final quality inspection, the actual low-carbon benefits are determined based on the material input amount corresponding to the reference state, the actual material input amount of the material spectrum segment that has passed the current verification, the change in power consumption between the current verification state and the reference state, the carbon emission factor per unit mass of material, and the carbon emission factor of electricity. When a non-conforming result occurs in the material spectrum segment after material release, the failure parameter increment, product specifications, material type, production speed, melt temperature, die head pressure, conservative quality margin, and process fluctuation value are written into the failure release status set. The conditions for state similarity are determined based on product specifications, material type, production speed, melt temperature, die head pressure, conservative mass margin, and process fluctuation value. When the subsequent production state and the failed release state meet the state similarity condition, the corresponding failure parameter increment is excluded from the new recoverable redundant release domain. For the material spectrum segment that has been successfully verified, the control parameters, local material response, local quality response, actual material reduction, conservative quality margin, and actual low-carbon benefits are written into the verified state set. The verified state set is then used to update the local quality response matrix and recoverable redundancy release domain under the same production conditions in the future.

[0012] The beneficial effects of this invention are as follows: This invention establishes material spectrum segments, correlating actual material input, theoretical material demand, equipment operating parameters, and subsequent quality inspection results. It also incorporates the closed-loop invisible time formed by material residence, transportation, and inspection into the quality margin analysis, ensuring that material over-input judgment is no longer limited to simple input comparison. Furthermore, by combining quality parameter fluctuations, trends, and the equipment's subsequent compensation capabilities, a recoverable redundancy release domain is constructed, which can distinguish between material redundancy that can be safely compressed and protective material margins that need to be retained.

[0013] This invention employs a phased material release approach for candidate parameters entering the recoverable redundancy release domain, continuously tracking the corresponding cable segments along the material spectrum. Material release continues only after actual quality inspection results meet requirements, confirming the actual low-carbon benefits. When unqualified results occur, the failed parameters and corresponding production states are written into a failed release state set to shrink subsequent recoverable redundancy release domains. This reduces the risk of repeated ineffective material reduction and quality exceeding limits, ensuring that material saving results correspond to actual qualified products, and improving material utilization and low-carbon control reliability in the continuous cable manufacturing process. Attached Figure Description

[0014] Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 are within the scope of protection of the present invention.

[0016] This embodiment addresses the problem of consistently exceeding the required material quantity during continuous extrusion of cable insulation and sheath layers due to the long-term use of a fixed material safety margin to avoid insufficient thickness or out-of-tolerance outer diameter. Unlike methods that directly adjust screw speed and traction speed based on insulation or sheath thickness, this embodiment establishes a material spectrum relationship from the metering feed end to the final quality inspection position. It considers the closed-loop invisible time formed by material residence in the extrusion equipment, parameter execution, and quality inspection. Within this invisible time, it determines whether material redundancy can be safely released based on remaining quality margin, quality change trends, and the equipment's subsequent compensability. Only materials entering the recoverable redundancy release domain are subject to phased reduction in material input. Material savings and low-carbon benefits are confirmed after actual quality verification in the corresponding material spectrum segment.

[0017] like Figure 1 As shown, the steps of a low-carbon production method for improving material utilization in cable manufacturing are as follows: S1. Establish material spectrum segments and obtain the actual material input, theoretical material demand and quality test results corresponding to the same material spectrum segment.

[0018] During the continuous extrusion of the insulation or sheath layer, real-time data are collected on the metered feed rate, extruder screw speed, die head pressure, melt temperature, traction speed, production line speed, online thickness of the insulation or sheath layer, and the outer diameter of the finished product. When the product specifications, material type, and basic process formula remain unchanged, the production process is divided into multiple basic production segments based on a continuous and stable state. When the production line starts or stops, reel is changed, material batches are switched, or the screw speed or traction speed experiences continuous changes exceeding the stable fluctuation range, the boundaries of the production segments are re-established. The stable fluctuation range is determined by the normal fluctuation range of the screw speed and traction speed in a stable and qualified production segment of the same specification cable, and is recalibrated when the material type, die, or main process configuration changes.

[0019] The materials fed into the extruder are further assigned material spectrum segment numbers, enabling the materials at the input end to be associated with the corresponding cable segments formed at the output end. The equivalent material retention from the metering feed position to the die head outlet is obtained beforehand through extruder no-load calibration or stable production calibration. Starting from the moment the i-th feeding segment enters the extruder, the actual output mass of the extruder is accumulated. When the accumulated output mass reaches the equivalent material retention, it is determined that the material from that feeding segment begins to exit from the die head. After the material leaves the die head, the material movement length is accumulated based on the real-time speed of the production line. When the accumulated movement length reaches the actual path distance between the die head outlet and the online quality inspection device, the quality inspection data at that moment and thereafter are assigned to the i-th material spectrum segment.

[0020] When the extruder is not equipped with a direct mass flow rate detection device, the actual output mass flow rate is obtained based on the weight loss data of the metering feed device and the calibrated screw speed-extrusion flow rate relationship, and then corrected using the material balance results under continuous and stable production conditions. Therefore, the same material spectrum segment should at least include the actual material input, corresponding production length, die head output status, online thickness, finished product outer diameter, and corresponding equipment parameters.

[0021] For the i-th material spectrum segment, the theoretical material requirement is calculated based on the product structural dimensions. For circular insulation or sheathing layers, the target material volume is calculated based on the target outer diameter, target inner diameter, material density, and the effective length of the corresponding segment, and the theoretical material requirement is obtained based on the material's process correction coefficient; the actual material input is obtained based on the metering and feeding results, and the material input residual is calculated. The material process correction coefficient is determined by the ratio of the actual material consumption per unit length of a stable and qualified production section under the same specifications, material type, and mold conditions to the geometric theoretical material quantity per unit length calculated based on the target inner and outer diameters and material density. The median of the corresponding ratios of multiple stable and qualified production sections is taken as the current material process correction coefficient. It is recalibrated when the product specifications, material type, or mold changes.

[0022]

[0023] In the formula, Let be the material delivery residual for the i-th material spectrum segment; This represents the actual material input amount for the i-th material spectrum segment; Let be the theoretical material requirement for the i-th material spectrum segment; A positive lower limit is set to prevent calculation instability caused by an insufficient theoretical material demand. When the material input residual is greater than the residual identification threshold, it only indicates that there is a material input exceeding the theoretical demand in the current material spectrum segment, and does not directly generate a material reduction instruction.

[0024] When metering and feeding data, production line speed, or quality inspection data are missing, causing the feeding section and quality section to not form a complete spectrum relationship, the corresponding material spectrum section will be marked as an invalid section and will not participate in subsequent material release. The residual identification threshold is determined by the material feeding residual distribution of cables of the same specification under a stable and qualified production state, and sections with start-up / stop, reel change, and abnormal shutdown will be excluded.

[0025] S2. Calculate the conservative mass margin considering the closed-loop invisible time and identify stable material redundancy that can be further analyzed.

[0026] For material spectrum segments in S1 where the material feeding residual exceeds the residual identification threshold, key quality parameters directly related to material shortage are obtained, including the minimum and average thickness of the insulation or sheath layer, and the outer diameter of the finished product. The control system not only determines whether to reduce material based on the static distance between the current quality parameters and the allowable boundary, but also further determines the closed-loop invisible time between a change in control parameters and the acquisition of the corresponding actual quality detection result. This closed-loop invisible time includes at least the material residence time within the extruder, the material conveying time from the die head to the quality detection position, and the detection time window required to form a stable quality detection result.

[0027] For the k-th quality parameter with a lower limit requirement, the conservative residual margin is calculated according to the following formula:

[0028] In the formula, It represents the conservative residual margin of the k-th quality parameter in the i-th material spectrum segment; This represents the segment mean of the corresponding quality parameter; and These are the lower and upper limits of the corresponding quality parameters, respectively. This refers to the fluctuation of this quality parameter within the current and preceding consecutive effective material spectrum segment; The slope of the quality parameter as a function of the production process; For closed-loop invisible time; This is the fluctuation protection factor. For mass parameters subject to upper limit constraints, it is calculated in a corresponding manner based on the distance between the allowable upper limit and the current mass parameter.

[0029] The minimum value among the conservative margins corresponding to each key quality parameter is taken as the conservative mass margin for the current material spectrum segment:

[0030] In the formula, This represents the conservative mass margin for the i-th material spectrum segment; to These represent the conservative margins for each critical mass parameter in this material spectrum segment. Using the minimum value ensures that subsequent material release is limited when any critical mass parameter approaches the allowable boundary.

[0031] Specifically, for each key quality parameter, the standard deviation of the quality parameter in the current material spectrum segment and its preceding consecutive effective material spectrum segments is divided by the corresponding quality tolerance bandwidth to obtain the random fluctuation component; the product of the slope of the mean change of the quality parameter segment in adjacent material spectrum segments and the average duration of the current material spectrum segment is divided by the corresponding quality tolerance bandwidth to obtain the trend fluctuation component; the larger value of the random fluctuation component and the trend fluctuation component is taken as the fluctuation characterization value of the corresponding key quality parameter, and the maximum value among the fluctuation characterization values ​​of each key quality parameter is taken as the process fluctuation value. The minimum number of segments for a series of consecutive material spectrum segments is taken as the smallest integer that ensures the cumulative segment duration is not less than one closed-loop invisible time.

[0032] The process fluctuation value is further obtained based on the fluctuation amplitude and slope of the quality parameters in continuous material spectrum segments. When the material input residual in several consecutive material spectrum segments is consistently higher than the residual identification threshold, the conservative quality margin is higher than the quality protection line, and the process fluctuation value is lower than the process fluctuation threshold, the material portion exceeding the theoretical requirement is marked as stable material redundancy; otherwise, the corresponding over-input portion is treated as protective material margin and is not allowed to be automatically released. The quality protection line, fluctuation protection coefficient, and process fluctuation threshold are determined by verification data of cables of the same specification under stable and qualified production conditions, and are recalibrated when the material type, mold, or detection location changes.

[0033] S3. Construct a recoverable redundant release domain based on local process response and closed-loop invisible time.

[0034] For the stable material redundancy determined by S2, the control system further determines whether, if this portion of material is reduced, the production equipment still has sufficient process adjustment space to prevent quality parameters from exceeding allowable boundaries before new, accurate quality test results appear. The changes in control parameters and corresponding changes in material input are extracted from the verified material spectrum of the current product specification to establish local material response relationships. Simultaneously, the correspondence between changes in control parameters and changes in minimum insulation thickness, average thickness, and finished product outer diameter is extracted to establish a local quality response matrix.

[0035] The current adjustable control parameter vector is denoted as:

[0036] In the formula, Let be the adjustable control parameter vector for the i-th material spectrum segment; The screw rotation speed; For traction speed; This is for metering and controlling the feed amount; the superscript T indicates transpose. If the equipment does not support online adjustment of a certain parameter, the corresponding parameter should be deleted from the control parameter vector.

[0037] Using validated adjacent material spectrum segments, a local quality response matrix and a local material response vector are obtained through a local least squares method with regularization terms. These are used to represent the local responses of small-range control parameter changes to the quality parameter and material input, respectively. For the candidate parameter increment for which material input is to be reduced, the quality change under the current control state is predicted based on the local quality response matrix, and a prediction uncertainty protection quantity is formed based on the quality fluctuation obtained from S2.

[0038] The prediction uncertainty protection amount is determined based on the prediction error of the local quality response matrix in the validated material spectrum segment. For each key quality parameter, the absolute error between the predicted value and the corresponding measured value is statistically analyzed, and the high quantile value corresponding to the preset coverage rate in the independent validation samples is taken as the prediction uncertainty protection amount for the corresponding key quality parameter. When there are insufficient effective validation samples, the larger value between the repeatability error of the corresponding quality detection device and the fluctuation of the current quality parameter is used as the prediction uncertainty protection amount. The model validation threshold is determined by the prediction error distribution of the validated material spectrum segment of the same specification cable, taking the error quantile value that meets the preset coverage rate, and recalibrating when the material type, mold, or main process configuration changes.

[0039] The local quality response matrix is ​​denoted as... The local material response vector is denoted as The increment of the candidate parameter is denoted as When the number of effective local samples is insufficient to form a reliable local quality response matrix, or when the condition number of the local quality response matrix exceeds the upper limit of stable calculation, the recoverable redundancy release domain is not expanded, and the most recently verified conservative release domain is adopted; if no verified release domain exists, the current process parameters are maintained.

[0040] Divide the closed-loop invisible time by the average duration of the current material spectrum segment and round up to obtain the number of recovery observation segments. Within the corresponding recovery observation segment range in the future, combine the allowable range of each control parameter, the maximum single adjustment amount and the adjustment rate limit to form a set of subsequent executable compensation parameters.

[0041] The number of observation segments restored is recorded as For a candidate material reduction parameter increment, it is considered a recoverable material reduction parameter only if the following conditions are met simultaneously: the predicted key quality parameters, after deducting the prediction uncertainty, still do not exceed the quality allowable boundary; the predicted quality trajectory will not cross the quality boundary before the next actual quality feedback is generated; if the predicted quality parameter continues to approach the boundary, then under the current equipment allowable parameter range and single adjustment limit, there exists at least one set of subsequent compensation parameters that enable the quality parameter to return to within the quality protection line within the recovery observation section.

[0042] All parameter increments that meet the above conditions and can reduce material input are combined into a recoverable redundancy release domain for the current material spectrum segment. Therefore, the amount of material that can be released is not determined solely by the material delivery residual, nor is it simply obtained by multiplying the current quality margin by an adjustment factor. Instead, it is determined jointly by the current material over-delivery, the closed-loop invisible time, the most unfavorable quality change, and the equipment's subsequent compensability. If there is no parameter increment that meets the conditions, material release will not be performed even if the current material delivery residual is high.

[0043] S4. Implement phased material release within the recoverable redundancy release domain, and use material spectrum quality verification as a condition for continued release.

[0044] In the recoverable redundant release domain Several candidate material reduction parameter schemes are generated. For each candidate scheme, the expected reduction in material mass is obtained based on the local material response relationship, and the expected carbon emission reduction at the material end is calculated based on the corresponding material unit mass carbon emission factor. When a candidate scheme changes the power consumption of the extruder or traction equipment, the incremental power consumption is predicted based on verified operating data, and a provisional low-carbon benefit for the candidate scheme is formed.

[0045] In the formula, The provisional low-carbon benefits for the candidate scheme of the i-th material spectrum segment; The expected reduction in material mass for the candidate solution; The carbon emission factor per unit mass of the corresponding material; This represents the increase in energy consumption of the candidate solution relative to the current state. This is the carbon emission factor for electricity. The provisional low-carbon benefit is only used for ranking multiple candidate schemes that meet quality and safety conditions and is not recorded as actual carbon emission reductions already achieved.

[0046] The carbon emission factor per unit mass of materials is preferentially based on the carbon footprint data of materials provided by the material supplier and verified by the enterprise; when corresponding material data is unavailable, the carbon emission factor of similar materials in the enterprise's unified carbon emission accounting database is used. The electricity carbon emission factor adopts the electricity emission factor currently used by the enterprise in its carbon emission accounting, and the source and version of each carbon emission factor are recorded; when the source or accounting method of the carbon emission factor changes, the corresponding low-carbon benefits are recalculated.

[0047] Candidate schemes with tentatively positive low-carbon benefits are ranked from highest to lowest based on their predicted mass margin. If the predicted mass margins are the same, they are ranked from smallest to largest based on the magnitude of parameter changes. The candidate scheme with the best ranking is selected as the target release scheme. The target release scheme does not execute the entire material reduction adjustment at once; instead, it first executes the first-stage detection release. The first-stage detection release is constrained by the equipment's minimum stable adjustment, the current conservative remaining mass margin, and the prediction uncertainty. The materials used in the first-stage release are assigned independent material family labels.

[0048] Specifically, the first-stage detection release begins with the minimum stable adjustment of the equipment and is limited to not exceeding the total adjustment corresponding to the target release plan. Key quality parameters after the first-stage detection release are predicted using the local quality response matrix. If the conservative quality margin after deducting the prediction uncertainty protection amount is still higher than the quality protection line, the detection release is permitted; otherwise, the first-stage material release is not executed. After the first-stage verification is successful, the release amounts in subsequent stages increase progressively according to the same rules, and each stage must not exceed the remaining adjustment amount of the target release plan.

[0049] The control system continues to track the batch of materials according to the material hierarchy progression relationship in S1 until the corresponding cable section formed by this batch of materials passes the online quality inspection position. It obtains the actual minimum insulation or sheath thickness, average thickness, and finished product outer diameter corresponding to the first stage release, and recalculates the conservative quality margin. Only when the actual material input decreases in the predicted direction, the conservative quality margin is not lower than the quality protection line, the process fluctuation value does not exceed the process fluctuation threshold, and the deviation between the actual quality change and the predicted result of the local quality response matrix does not exceed the model verification threshold, is the first stage release considered valid and the next stage of material release allowed. If any condition is not met, the material reduction is immediately stopped, and the system reverts to the most recently verified parameters before executing the first stage detection release.

[0050] S5. Confirm actual low-carbon benefits based on verified material spectrum segments, and use failure states to reverse correct recoverable redundant release domains.

[0051] After completing the release verification of a material spectrum segment, the actual material savings are confirmed only for the material spectrum segments that meet the product requirements in the final quality inspection. Using the most recent verified stable segment under the same product specifications, material type, and similar production speed conditions before material release as a reference state, the actual material input per unit length is converted to the current segment's production length to obtain the reference material input. The actual low-carbon benefits after verification are calculated based on the actual material input of the currently verified segment and the actual change in electrical energy relative to the reference state. Here, "similar production speed" means that the difference between the production speed of the reference state and the current material spectrum segment does not exceed the speed matching threshold determined by stable and qualified production data of cables of the same specification.

[0052]

[0053] In the formula, The actual low-carbon benefit of the i-th material spectrum segment after quality verification; This refers to the material input amount after converting the reference state to the current production length of the section; This represents the actual material input amount for the currently verified material spectrum segment; and These represent the energy consumption corresponding to the current verification state and the reference state, respectively. and The meaning is consistent with S4. Only when the final quality of the corresponding material spectrum segment is qualified will the actual low-carbon benefits be recorded in the low-carbon production results.

[0054] If the material spectrum segment corresponding to the material reduction produces unqualified results, the predicted material savings will not be confirmed as carbon emission reductions. Instead, the increment of the failure parameters, the production status before the failure, and the corresponding quality changes will be written into the failure release status set. The failure release status includes at least the product specifications, material type, production speed, melt temperature, die head pressure, conservative quality margin, process fluctuation value, and the increment of the failure parameters.

[0055] Specifically, identical product specifications and material types are used as prerequisites for determining state similarity. Production speed, melt temperature, die head pressure, conservative mass margin, and process fluctuation values ​​are normalized according to the allowable range of the corresponding equipment or the statistical scale of stable samples. If the absolute deviation between the subsequent production state and the failed release state on the above normalized parameters does not exceed the corresponding state similarity threshold, the state similarity condition is deemed met. Each state similarity threshold is determined from verified failed release states and their adjacent stable state data, and is recalibrated when material type, mold, or main process configuration changes.

[0056] When a subsequent production state meets the state similarity condition with a failed release state, the resource is released from the new recoverable redundancy domain. The failed parameter increment and its adjacent parameter range are excluded, causing the recoverable redundancy release domain to shrink in a safe direction, avoiding repeated material releases that have already failed under the same operating conditions. Only when there are substantial changes in the material batch, production speed, temperature conditions, or basic process conditions, and after verification in a new stable material spectrum segment, is the recovery of the excluded area recalculated.

[0057] For the material spectrum segment that has been successfully verified, the control parameters, local material response, local quality response, actual material reduction, conservative quality margin, and actual low-carbon benefits are written into the verified state set and used to update the local quality response matrix and recoverable redundancy release domain under the same production state in the future.

[0058] Through S1 to S5, this embodiment forms a closed-loop production process of "material spectrum segment establishment - material over-investment identification - closed-loop invisible time compensation - conservative quality margin calculation - recoverable redundancy release domain construction - phased material release - corresponding material spectrum quality verification - actual low-carbon benefit confirmation - failure release domain reverse contraction".

[0059] This embodiment does not achieve material savings simply by controlling the thickness of the insulation or sheath layer near the target value. Instead, it further assesses whether the production status still has the ability to restore the quality parameters to a safe range during the quality feedback lag caused by the extrusion material's residence, conveying, and testing. Therefore, even if two production sections have the same material input residual and the same current insulation thickness, if one production section cannot recover before quality feedback is formed due to large quality fluctuations, long response lags, or insufficient equipment residual compensation capacity, its corresponding material redundancy will not enter the recoverable redundancy release domain; only material redundancy with actual recovery capability is released. Material carbon emission reduction is not confirmed when the reduction parameters are calculated, but rather after the corresponding material spectrum section undergoes actual quality verification, thus avoiding the situation where rework or scrap due to material reduction is still counted as low-carbon benefit.

[0060] The parameters involved in the normalization process were dimensionless before calculation, based on the corresponding quality tolerance zone, equipment allowable range, or stable sample statistical scale. Parameters with clear physical meaning, such as material quality, power consumption, time, and carbon emissions, retained their corresponding dimensions. Each identification threshold, quality protection line, fluctuation protection coefficient, stability calculation upper limit, and model validation threshold was determined based on stable and qualified production data of products of the same specification, equipment allowable range, and process validation results, and was recalibrated when material type, mold, detection location, or main process configuration changed.

[0061] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, as a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired or wireless (e.g., infrared, wireless, microwave, etc.) means. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that includes one or more sets of available media. The available medium can be a magnetic medium (e.g., floppy disk, ATA hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium. The semiconductor medium can be a solid-state ATA hard disk.

[0062] It should be understood that in the various embodiments of this application, the order of the above-mentioned processes does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0063] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0064] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0065] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment, depending on actual needs.

[0066] In addition, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0067] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable ATA hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0068] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A low-carbon production method for improving material utilization in cable manufacturing, characterized in that, include: S1. Establish a material spectrum section during the continuous extrusion process of cable insulation or sheath layer, and correlate the actual material input, theoretical material demand and quality test results to determine the material input residual. S2. Determine the closed-loop invisible time between the change of control parameters and the acquisition of the corresponding quality test results. Combine the fluctuation and trend of quality parameters to determine the conservative quality margin and identify the redundancy of stable materials. S3. Construct a recoverable redundancy release domain based on the local process response, closed-loop invisible time, and subsequent compensability of the equipment in the verified material spectrum segment. S4. Generate candidate material reduction parameter schemes within the recoverable redundancy release domain, implement phased material release for the selected candidate material reduction parameter schemes, and determine whether to continue material release or restore to the most recently verified parameters based on the actual quality test results of the corresponding material spectrum segment. S5. Confirm the actual low-carbon benefits of material spectrum segments that have passed quality verification, and shrink the subsequent recoverable redundant release domains based on the failure release status.

2. The low-carbon production method for improving material utilization in cable manufacturing process according to claim 1, characterized in that, S1 includes: Collect and measure feed rate, extruder screw speed, die head pressure, melt temperature, traction speed, production line speed, online thickness of insulation or sheath layer and outer diameter of finished product, and establish new production section boundaries when the production line starts or stops, changes discs, switches material batches, or when the screw speed or traction speed changes continuously beyond the stable fluctuation range. The material fed into the extruder is assigned a material spectrum segment number, and the time when the corresponding material starts to be output from the die head is determined based on the equivalent material retention between the metering feed position and the die head outlet. After the corresponding material is output from the machine head, the material movement length is accumulated according to the real-time speed of the production line. When the accumulated material movement length reaches the actual path distance between the machine head outlet and the quality inspection device, the corresponding quality inspection data is assigned to the corresponding material spectrum segment. The theoretical material requirement is determined based on the target outer diameter, target inner diameter, material density, effective length of material spectrum segment, and material process correction coefficient. The actual material input is determined based on the metering and feeding results. The material input residual is determined based on the degree of deviation between the actual material input and the theoretical material requirement.

3. A low-carbon production method for improving material utilization in cable manufacturing process according to claim 2, characterized in that, S2 includes: Obtain the minimum thickness, average thickness, and finished product outer diameter of the insulation or sheath layer as key quality parameters; The material residence time inside the extruder, the conveying time of the material from the die head to the quality inspection position, and the inspection time window required to form a stable quality inspection result are collectively defined as the closed-loop invisible time. For critical quality parameters with lower limit requirements, the conservative remaining margin of the corresponding critical quality parameter is determined by deducting the margin occupied by the quality parameter fluctuation, change slope, closed-loop invisible time and fluctuation protection coefficient, based on the distance between the segment mean of the corresponding critical quality parameter and the allowable lower limit. For critical quality parameters with upper limit requirements, the conservative remaining margin of the corresponding critical quality parameter is determined by deducting the margin occupied by the quality parameter fluctuation, change slope, closed-loop invisible time and fluctuation protection coefficient, based on the distance between the allowable upper limit and the segment mean of the corresponding critical quality parameter. The minimum value among the conservative margins of each key quality parameter is determined as the conservative mass margin of the corresponding material spectrum segment.

4. A low-carbon production method for improving material utilization in cable manufacturing process according to claim 3, characterized in that: The process fluctuation value is determined based on the fluctuation amplitude and slope of key quality parameters within the continuous material spectrum segment; When the residual of material delivery in several consecutive material spectrum segments is continuously higher than the residual identification threshold, the conservative quality margin is higher than the quality protection line, and the process fluctuation value is lower than the process fluctuation threshold, the material portion that exceeds the theoretical material demand is identified as stable material redundancy. If any of the above conditions are not met, the corresponding over-feed portion of material will be determined as a protective material margin, and automatic release of the protective material margin will be prohibited. The residual identification threshold, quality protection line, fluctuation protection coefficient, and process fluctuation threshold are determined based on verification data of cables of the same specification under stable and qualified production conditions, and are recalibrated when the material type, mold, or quality inspection location changes.

5. A low-carbon production method for improving material utilization in cable manufacturing process according to claim 4, characterized in that, S3 includes: From the verified material spectrum segments of cable product specifications corresponding to the current material spectrum segment, extract the correspondence between the change in control parameters and the change in material input to establish a local material response relationship, and extract the correspondence between the change in control parameters and the changes in the minimum thickness, average thickness and outer diameter of the insulation or sheath layer to establish a local quality response matrix. The adjustable control parameter vector is composed of parameters that can be adjusted online by the equipment, including screw speed, traction speed, and metering feed control. The mass change corresponding to the increment of candidate parameters is predicted based on the local mass response matrix, and the prediction uncertainty protection amount is determined based on the mass fluctuation amount. Candidate parameter increments that do not exceed the quality allowable boundary after deducting the prediction uncertainty protection amount, do not cross the quality allowable boundary during the closed-loop invisible time, and have subsequent compensation parameters that can enable the corresponding key quality parameters to return to the quality protection line within the recovery observation section are identified as recoverable material reduction parameters. The recoverable material reduction parameters that can reduce material input are combined into a recoverable redundancy release domain.

6. A low-carbon production method for improving material utilization in cable manufacturing process according to claim 5, characterized in that: Based on the verified adjacent material spectrum segments, the local quality response matrix and local material response vector are obtained by the local least squares method with regularization term. The local material response vector is used to characterize the local response relationship between changes in control parameters and changes in material input. The number of observation segments to be restored is determined based on the closed-loop invisible time and the average duration of the material spectrum segment. Within the recovery observation section, a set of subsequent executable compensation parameters is formed by combining the allowable range of each control parameter, the maximum single adjustment amount, and the adjustment rate limit. When the number of effective local samples is insufficient to form a reliable local quality response matrix, or when the condition number of the local quality response matrix exceeds the upper limit of stable computation, the recoverable redundancy release domain is not expanded, and the most recently verified conservative release domain is adopted. If no validated conservative release domain exists, maintain the current process parameters.

7. A low-carbon production method for improving material utilization in cable manufacturing process according to claim 5, characterized in that, S4 includes: Generate candidate reduction parameter schemes within the recoverable redundancy release domain; The expected reduction in material mass corresponding to each candidate material reduction parameter scheme is determined based on the local material response relationship. The provisional low-carbon benefits are determined based on the expected reduction in material mass, the carbon emission factor per unit mass of material, the incremental power consumption and the carbon emission factor of electricity corresponding to the candidate material reduction parameter scheme. From the candidate fuel reduction parameter schemes with tentatively positive low-carbon benefits, the candidate fuel reduction parameter schemes are ranked according to the predicted mass margin and the magnitude of parameter changes, and the target release scheme is determined. The first-stage detection release amount is determined based on the minimum stable adjustment amount of the equipment, the conservative mass margin, and the prediction uncertainty, and the materials for performing the first-stage material release are assigned independent material family labels. According to the material genealogy progression relationship, the materials released in the first stage are tracked to the quality inspection location, and the actual quality inspection results of the corresponding cable sections are obtained; When the actual material input decreases in the predicted direction, the conservative quality margin is not lower than the quality protection line, the process fluctuation value is not higher than the process fluctuation threshold, and the deviation between the actual quality change and the predicted result of the local quality response matrix does not exceed the model verification threshold, the next stage of material release will continue. If any of the above conditions are not met, the material release will be stopped and the parameters will be restored to the most recent verified parameters before the first stage of material release.

8. A low-carbon production method for improving material utilization in cable manufacturing process according to claim 7, characterized in that, S5 includes: The verified stable section under the same product specifications, same material type and similar production speed conditions most recently before material release is used as the reference state, and the actual material input per unit length of the reference state is converted to the production length of the current material spectrum section. For material spectrum segments that have passed the final quality inspection, the actual low-carbon benefits are determined based on the material input amount corresponding to the reference state, the actual material input amount of the material spectrum segment that has passed the current verification, the change in power consumption between the current verification state and the reference state, the carbon emission factor per unit mass of material, and the carbon emission factor of electricity. When a non-conforming result occurs in the material spectrum segment after material release, the failure parameter increment, product specifications, material type, production speed, melt temperature, die head pressure, conservative quality margin, and process fluctuation value are written into the failure release status set. The conditions for state similarity are determined based on product specifications, material type, production speed, melt temperature, die head pressure, conservative mass margin, and process fluctuation value. When the subsequent production state and the failed release state meet the state similarity condition, the corresponding failure parameter increment is excluded from the new recoverable redundant release domain. For the material spectrum segment that has been successfully verified, the control parameters, local material response, local quality response, actual material reduction, conservative quality margin, and actual low-carbon benefits are written into the verified state set. The verified state set is then used to update the local quality response matrix and recoverable redundancy release domain under the same production conditions in the future.

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