Coating material loading capacity real-time monitoring device for composite paper production

Abstract

The utility model provides a coating material loading capacity real-time monitoring device for composite paper production, which comprises a detection module used for collecting the variable length delta X of paper in the composite paper production process in real time; the input module is used for manually inputting the film width Y of the composite film and the breadth Z of the paper laminated with the composite film; the sensor module comprises a platform scale which is used for measuring the use amount delta L glue, delta L varnish and delta L back coating liquid of glue, varnish and back coating liquid used when the composite paper with a certain length is produced; the data processing unit is used for calculating the coating material carrying capacity of the composite paper in unit area according to the following formula: glue carrying capacity U1 glue = 106 * delta L glue / (delta X * Y), and the unit is g / m < 2 >; the varnish carrying capacity U2 varnish is 106 * delta L varnish / (delta X * Z), and the unit is g / m < 2 >; or the carrying capacity U3 of the back coating liquid is equal to 106 * delta L back coating liquid / (delta X * Z), and the unit is g / m < 2 >.

Description

TECHNICAL FIELD

[0001] The utility model relates to the composite paper production monitoring technical field, concretely relates to a kind of coating material loading real-time monitoring device for composite paper production. BACKGROUND

[0002] In the composite paper production field, especially in the industry such as cigarette case printing which has higher requirements on paper quality, it is crucial to accurately control the amount of glue, varnish and back coating liquid on composite paper. However, the existing composite industry factory has significant deficiencies in monitoring the amount of glue, varnish and back coating liquid on the unit area of composite paper during production.

[0003] Currently, the factory cannot obtain the specific amount data of these coating materials in real time during on-site production. The machine operator can only calculate the amount of glue, varnish and back coating liquid on composite paper by weighing a certain length of composite paper with a scale, which has many drawbacks.

[0004] For example, the amount of glue on the unit area of composite paper directly affects the bonding strength of the aluminum layer and the paper. If the amount of glue is not appropriate, it will affect the die-cutting production process after printing, which may cause problems such as aluminum explosion and ink explosion. The amount of varnish on the unit area of composite paper significantly affects the bonding strength of ink and paper during the printing process. If the amount of varnish is too small, the bonding strength of ink is poor; if the amount of varnish is too large, the varnish is too thick after coating on the composite paper, which may cause paper sticking. The amount of back coating liquid on the unit area of composite paper affects the control of the water content data of composite paper. If the amount is too small, the water locking function of composite paper is poor, and the paper is prone to deformation, which affects the quality of each process during production in the printing factory; if the amount is too large, it may accumulate on the back of the paper, causing quality problems such as sticking on the front surface when stacking the paper.

[0005] On the other hand, the existing method cannot be monitored in real time, and cannot timely discover abnormal situations in the production process. Moreover, relying solely on personnel to calculate the amount of each variable coating material on site is difficult to achieve intuitive and reliable data management. Production data cannot be detected in real time through an online system and transmitted to the factory display screen. When data anomalies occur, timely warning and alerting are also difficult, and machine operators are difficult to adjust production parameters in time, which is difficult to meet the requirements of customers for high-quality products.

[0006] In summary, the existing technology in the composite paper production process restricts the improvement of product quality and the efficient management of the production process, and there is an urgent need for a device that can monitor the amount of variable coating material on the unit area of composite paper in real time to solve these problems and meet the high-quality production needs of the industry such as cigarette case printing. UTILITY MODEL CONTENT

[0007] In view of the above technical problems, the technical objective of the utility model is to solve the problem that the paper coating material consumption per unit area cannot be monitored in real time in the production of the existing composite paper, to realize the standardization, dataization and normalization management of the production process, and to meet the high-quality production requirements.

[0008] According to the technical scheme of the utility model, a coating material loading real-time monitoring device for composite paper production is provided, which comprises:

[0009] A detection module is used to collect the variable length ΔX of the paper in the production process of the composite paper in real time;

[0010] An input module is used to manually input the film width Y of the composite film and the width Z of the paper after being attached to the composite film;

[0011] A sensor module comprises a scale, which is used to measure the consumption ΔL of the glue, varnish and back coating liquid used when producing a certain length of the composite paper, and transmit the data to a data processing unit; 胶水 , ΔL 清漆 and ΔL 背涂液

[0012] The data processing unit is connected with the detection module, the input module and the sensor module and comprises a programmable logic controller, which is used to calculate the coating material loading per unit area of the composite paper according to the following formula:

[0013] The glue loading U1 胶水 = 10 6 × ΔL 胶水 / (ΔX×Y), unit: g / m 2 ;

[0014] The varnish loading U2 清漆 = 10 6 × ΔL 清漆 / (ΔX×Z), unit: g / m 2 ; or

[0015] The back coating liquid loading U3 背涂液 = 10 6 × ΔL 背涂液 / (ΔX×Z), unit: g / m 2 . BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 The structure schematic diagram of the coating material loading real-time monitoring device for composite paper production according to one specific embodiment of the utility model is shown. DETAILED DESCRIPTION​

[0017] The utility model will be described in further detail below in combination with the drawings and specific embodiments. It will be understood that other embodiments are considered and can be implemented without departing from the scope or spirit of the utility model. Therefore, the following detailed description is non-limiting.

[0018] Unless otherwise indicated, all numbers expressing features, quantities and physical characteristics in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing teachings disclosed herein. The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (as well as fractions thereof) and all ranges between the recited ranges, e.g., 1 to 5 includes 1, 1.1, 1.3, 1.5, 2, 2.75, 3, 3.80, 4, and 5, etc.

[0019] As described above, the utility model focuses on the field of composite paper production, and is committed to solving the key technical problems existing in the current industry. In the production process of composite paper, accurate control of the amount of glue, varnish and back coating liquid on the unit area of paper is crucial to product quality. However, the prior art has many drawbacks. On the one hand, the factory cannot obtain the amount data of these coating materials in real time in the production process, and the machine personnel need to manually measure and calculate, which is low in efficiency and prone to errors. On the other hand, improper amount control will cause a series of product quality problems, such as unreasonable amount of glue affecting the adhesion of aluminum layer and paper, leading to aluminum and ink explosion phenomenon in the die cutting process after printing; improper amount of varnish affecting the adhesion of ink and paper, causing sticking problem; improper amount of back coating liquid affecting the moisture content of paper, leading to paper deformation or lamination sticking. In addition, the lack of real-time monitoring and data management means cannot timely discover and solve the abnormal conditions in the production process, and it is difficult to meet the strict requirements of cigarette box printing and other industries for high-quality products. The utility model aims to overcome these difficulties, and realizes the optimization of production process and the improvement of product quality.

[0020] According to the technical scheme of the utility model, a coating material loading real-time monitoring device for composite paper production is provided, characterized in that it comprises:

[0021] The detection module comprises an encoder or a photoelectric sensor, and is used for real-time acquisition of the variable length of the paper in the production process of the composite paper;

[0022] The input module is used for manually inputting the film width Y of the composite film and the width of the paper after being attached to the composite film;

[0023] A sensor module comprising a scale for measuring the amount of glue, varnish and back coating liquid used in the production of a certain length of the composite paper and transmitting data to a data processing unit;

[0024] A data processing unit connected with the detection module, the input module and the sensor module and comprising a programmable logic controller for calculating the coating material loading of the composite paper per unit area.

[0025] In particular, the utility model provides a kind of coating material loading real-time monitoring device for composite paper production, comprising:

[0026] Detection module comprising encoder or photoelectric sensor, for real-time acquisition of the variable length ΔX of paper in the production process of composite paper;

[0027] Input module for manually inputting the film width Y of composite film and the width Z of the paper after being attached to the composite film;

[0028] Sensor module comprising a scale for measuring the amount of glue, varnish and back coating liquid used in the production of a certain length of the composite paper and transmitting data to a data processing unit; 胶水 , ΔL 清漆 And ΔL 背涂液 , and transmitting data to a data processing unit;

[0029] Data processing unit connected with the detection module, the input module and the sensor module and comprising a programmable logic controller for calculating the coating material loading of the composite paper per unit area according to the following formula:

[0030] Glue loading U1 胶水 =10 6 ×ΔL 胶水 / (ΔX×Y), unit g / m 2 ;

[0031] Varnish loading U2 清漆 =10 6 ×ΔL 清漆 / (ΔX×Z), unit g / m 2 ;

[0032] Back coating liquid loading U3 背涂液 =10 6 ×ΔL 背涂液 / (ΔX×Z), unit g / m 2 .

[0033] Figure 1This diagram illustrates the structure of a real-time monitoring device 100 for coating material load in composite paper production, according to a specific embodiment of the present invention. Specifically, the real-time monitoring device 100 for coating material load in composite paper production includes: a detection module 1, which includes an encoder or photoelectric sensor for real-time acquisition of the variable length ΔX of the paper during the composite paper production process; an input module 2 for manually inputting the film width Y of the composite film and the width Z of the paper after laminating the composite film; and a sensor module 3, which includes a weighing scale 4 for measuring the amount ΔL of glue, varnish, and backing liquid used in producing a certain length of composite paper. 胶水 ΔL 清漆 and ΔL 背涂液 The data is then transmitted to the data processing unit 5. The data processing unit 5 is connected to the detection module 1, the input module 2, and the sensor module 3, and includes a programmable logic controller 6. The programmable logic controller 6 is used to calculate the coating material load per unit area of ​​the composite paper according to the following formula: Adhesive load U1 胶水 =10 6 ×ΔL 胶水 / (ΔX×Y), in g / m 2 ; Varnish load U2 清漆 =10 6 ×ΔL 清漆 / (ΔX×Z), in g / m 2 Back coating liquid loading U3 背涂液 =10 6 ×ΔL 背涂液 / (ΔX×Z), in g / m 2 .

[0034] Specifically, the real-time monitoring device of this invention mainly consists of a detection module, an input module, a sensor module, a data processing unit, and other auxiliary modules (such as a display module, an early warning module, a storage module, and a communication module). These modules can cooperate with each other to achieve real-time monitoring and management of the variable coating material load per unit area of ​​composite production paper.

[0035] According to certain embodiments of the present application, the detection module is a component that realizes real-time collection of the variable length ΔX of the paper during the production of the composite paper. It can use various ways such as encoders or photoelectric sensors to complete this function. When using an encoder, the encoder is connected to the transmission roller of the composite paper production equipment. During the production of the composite paper, the rotation of the transmission roller will drive the paper to move, and the encoder can accurately calculate the moving distance of the paper, i.e., the unit variable composite paper length ΔX, by monitoring the number of rotations of the transmission roller and combining parameters such as the circumference of the transmission roller. If a photoelectric sensor is used, its working principle is to obtain ΔX by measuring the distance of the paper movement. For example, the photoelectric sensor can emit light, and when the paper passes, the light is blocked or reflected, and the sensor calculates the distance of the paper movement according to the time interval of the light change and its own measurement accuracy. In addition, the detection module can also include a photoelectric encoder installed at the shaft end of the composite paper roller. During the rotation of the composite paper roller, the photoelectric encoder will generate a pulse signal, and by counting the pulse signal and according to the resolution of the photoelectric encoder, the number of rotations is converted into the length change amount ΔX of the composite paper. This diversified design enables the detection module to adapt to different composite paper production equipment and production environments, ensuring the accuracy and stability of the length data collection.

[0036] According to certain embodiments of the present application, the input module is used for manually inputting parameters closely related to the production process, i.e., the film width Y of the composite film and the paper width Z after the composite film is attached. Considering the convenience of use of the operator and the actual production needs, the input module provides multiple input methods. One of them is a touch screen input module, and the operator can directly input the film width Y of the composite film and the paper width Z after the composite film is attached on the screen through touch operation. The touch screen input module has the advantages of intuitive and convenient operation, and can greatly improve the efficiency of data input. Another input method is a keyboard input module, which is equipped with a digital keyboard to facilitate the operator to accurately input related data. The keyboard input module is suitable for operators who have high requirements for data accuracy, and they can accurately input each value through the keys. Whether it is a touch screen input module or a keyboard input module, the input data can be transmitted to the subsequent data processing unit in time, providing necessary parameter support for calculating the coating material loading of the unit area composite paper.

[0037] According to certain embodiments of the present application, the sensor module is responsible for measuring the amount of glue, varnish and back coating liquid ΔL 胶水 , ΔL 清漆 and ΔL 背涂液The sensor module transmits the data to the data processing unit. One of the core components of the sensor module is a scale. In order to ensure high precision and reliability of the measurement, the scale in the utility model is preferably an electronic scale, and the measurement accuracy thereof can reach ±0.1 g. The high-precision measurement capability can accurately obtain the slight change of the amount of the coating material in the production process, and provide a reliable data basis for subsequent accurate calculation. In addition, preferably, in order to meet different production requirements and improve the storage and management efficiency of the data, the electronic scale is also provided with a data storage function, and at least 1000 groups of measurement data can be stored. The stored data can not only be used for subsequent data analysis and comparison, but also can ensure the integrity and traceability of the data in the case of data transmission failure or other special circumstances.

[0038] According to some preferred embodiments of the utility model, in addition to the scale, the sensor module can also include a liquid level sensor for assisting in monitoring the amount of glue, varnish and back coating liquid. In the actual production process, the liquid level sensor can be installed in the container for storing the glue, varnish and back coating liquid, and the usage amount of the coating material can be calculated by monitoring the change of the liquid level in the container in combination with the shape and size of the container and other parameters. The data of the liquid level sensor and the scale are complementary to each other, and the consumption of the coating material in the production process can be more comprehensively and accurately reflected.

[0039] According to some preferred embodiments of the utility model, in order to further improve the accuracy and pertinence of the measurement, the sensor module can also include a plurality of independent weighing units corresponding to the glue tank, the varnish tank and the back coating liquid tank respectively. Each independent weighing unit can monitor the weight change of the coating material in the corresponding tank in real time, avoid the mutual interference between different coating materials, and improve the measurement accuracy and reliability. For example, the independent weighing unit installed below the glue tank can accurately measure the usage amount of the glue, and provide more accurate data for calculating the glue load of the unit area of the composite paper.

[0040] According to some preferred embodiments of the utility model, the sensor module is also provided with a temperature sensor for monitoring the ambient temperature. In the actual production process, the change of the ambient temperature can affect the density and volume of the coating material, thereby affecting the measurement accuracy of the amount of the coating material. The temperature sensor transmits the monitored ambient temperature data to the data processing unit, and the data processing unit can perform temperature compensation calculation on the ΔL 胶水 , ΔL 清漆 and ΔL 背涂液 according to a preset algorithm, eliminate the influence of the temperature factor on the measurement result, and further improve the accuracy of the measurement data.

[0041] According to certain preferred embodiments of this utility model, the sensor module may further include a multi-channel solenoid valve assembly for separately controlling the supply lines of adhesive, varnish, and back coating liquid. During production, based on actual production needs and instructions from the data processing unit, the multi-channel solenoid valve assembly can precisely control the supply amount of each coating material, achieving accurate control of the production process. For example, when the data processing unit detects that the adhesive load per unit area of ​​composite paper is lower than a preset standard, the multi-channel solenoid valve assembly can increase the adhesive supply, ensuring the stability of the production process and the consistency of product quality.

[0042] According to the embodiment of this utility model, the data processing unit is the control component of the entire device. It is connected to the detection module, input module, and sensor module, and is responsible for the comprehensive processing and analysis of the data collected by each module. The data processing unit can use various types of processors, among which programmable logic controllers (PLCs) and microcontrollers are two common choices.

[0043] When the data processing unit uses a programmable logic controller (PLC), it has stable data processing capabilities and can reliably receive and process large amounts of data from other modules. The PLC, through a pre-written program, processes data based on the variable paper length ΔX collected by the detection module, the composite film width Y and paper width Z input by the input module, and the amounts of glue, varnish, and backing liquid U1 measured by the sensor module. 胶水 U2 清漆 and U3 背涂液 Calculate according to the following formula:

[0044] Adhesive load U1 胶水 =10 6 ×ΔL 胶水 / (ΔX×Y), in g / m 2 ;

[0045] Clear coat load U2 清漆 =10 6 ×ΔL 清漆 / (ΔX×Z), in g / m 2 ;

[0046] Back coating liquid loading U3 背涂液 =10 6 ×ΔL 背涂液 / (ΔX×Z), in g / m 2 .

[0047] By substituting the various parameters into the formula for calculation, the coating material load per unit area of ​​composite paper can be accurately obtained.

[0048] In addition, if the data processing unit adopts a single-chip microcomputer, the single-chip microcomputer has the characteristics of low power consumption and high integration, and is suitable for application scenarios with high requirements for cost and power consumption. The single-chip microcomputer can also complete the functions of receiving, processing and calculating data through the internal processor and related circuits. It can process the analog signals transmitted by the sensor module, convert the analog signals into digital signals through an analog-to-digital converter (ADC) for subsequent calculation and analysis. For example, the data processing unit can adopt an ARM Cortex-M4 microcontroller, which connects an analog-to-digital converter (ADC) through an SPI interface for receiving analog signals from the sensor module, and connects a detection module pulse signal through a GPIO interface. In this way, the single-chip microcomputer can accurately obtain the data of each module and perform efficient processing and calculation.

[0049] In order to realize more accurate control of the production process, the data processing unit is built-in EEPROM memory for storing preset threshold ranges of U1 胶水 , U2 清漆 and U3 背涂液 . These thresholds are dynamically loaded according to different product types to adapt to diversified production needs. For example, for different specifications of cigarette box printing composite paper, the requirements for the amount of glue, varnish and back coating liquid may be different, and the data processing unit can load the corresponding threshold range from the EEPROM memory according to the product type. When the calculated coating material loading per unit area of the composite paper exceeds the preset threshold range, the data processing unit will trigger the subsequent warning module or control the related equipment to adjust to ensure that the production process is always in a stable state.

[0050] Optionally, the coating material loading real-time monitoring device for composite paper production according to the present application also comprises a warning module. The warning module is connected with the data processing unit. When the data processing unit calculates that the coating material loading per unit area of the composite paper exceeds the preset normal range, the warning module will issue an alarm. Preferably, the alarm mode of the warning module includes multiple forms such as sound alarm and light flashing alarm. For example, when the glue loading per unit area of the composite paper is too high or too low, the warning module will issue a sharp sound alarm, and the corresponding indicator light will start to flash, attracting the attention of the operator. This timely warning mechanism can help the operator quickly discover abnormal conditions in the production process and take timely measures to adjust, avoiding product quality problems caused by abnormal coating material usage, and ensuring the continuity and stability of the production process.

[0051] According to the embodiment of the utility model, the device optionally further includes a communication module. The communication module is connected with the data processing unit, and its main function is to transmit the coating material loading data of the composite paper per unit area to a remote server for data analysis and management. The communication module supports 4G or 5G wireless communication network, and this high-speed and stable communication mode can ensure the rapid transmission of data. By transmitting the production data to the remote server, the enterprise can realize remote monitoring and centralized management of the production process. For example, the management personnel of the enterprise can access the remote server at any time and anywhere through a terminal device such as a mobile phone or a computer, view production data, analyze production trends, and make decisions in a timely manner. At the same time, the remote server can also deeply analyze a large amount of production data, mine the potential value behind the data, and provide strong support for the production optimization and strategic decision-making of the enterprise.

[0052] According to the technical scheme of the utility model, through the cooperative work of the detection module, the sensor module and the data processing unit, the real-time monitoring of the glue amount, the varnish amount and the back coating amount on the paper per unit area in the composite production process is realized. Compared with the traditional manual measurement and calculation method, the timeliness and accuracy of monitoring are greatly improved. For example, the traditional method may need to measure and calculate after a certain length of production, while the device can obtain data in real time and timely find the change of the coating material usage, providing a more timely basis for the adjustment of the production process.

[0053] In addition, the display module is arranged to make the production data directly visualized, so that the operator can intuitively see the coating material loading data of the composite paper per unit area, and can observe the change trend of the data over time in the form of a chart. This not only facilitates product data recording and product tracking, but also provides a more intuitive and scientific basis for production management. For example, by observing the chart, the operator can quickly judge whether the production process is stable and whether the production parameters need to be adjusted.

[0054] In addition, the existence of the early warning module enables the device to timely issue an alarm when the coating material loading of the composite paper per unit area exceeds the preset range, reminding the operator to make adjustments. This effectively avoids product quality problems caused by improper coating material usage, such as aluminum and ink explosion, sticking, paper deformation, etc., and ensures the stability of the production product quality. For example, when the glue loading is too high, the early warning module timely reminds the operator to reduce the glue supply amount, preventing problems such as aluminum and ink explosion, and improving the product qualification rate.

[0055] According to the technical scheme of the utility model, the storage module stores the production data for a long time, and provides rich data resources for production analysis and process optimization of enterprises. The communication module realizes remote transmission of data, and facilitates remote monitoring and centralized management of enterprises. For example, an enterprise can collect and analyze data of different production workshops through a remote server, find common problems in the production process, and uniformly optimize and improve the production process, thereby improving the overall production efficiency and management level of the enterprise.

[0056] The various modules in the utility model cooperate with each other, from data acquisition, input, processing, display to early warning, storage and transmission, forming a complete production monitoring and management system. The diversified design of different modules (such as the multiple acquisition modes of the detection module, the multiple input modes of the input module, the multiple selection of the data processing unit, etc.), so that the device can adapt to different production environments and needs, further optimize the production process, and improve the practicability and adaptability of the device. For example, on different composite paper production equipment, appropriate detection modules and data processing units can be selected according to the characteristics of the equipment to ensure that the device can better play a role.

[0057] In actual application, first, according to the production specification of the composite paper, the operator manually inputs the film width Y of the composite film and the paper width Z after the composite film is attached through the input module. The input module can select a touch screen input module or a keyboard input module, and is operated according to the habit and demand of the operator to ensure accurate data entry.

[0058] After the production process is started, the detection module starts to work. If an encoder is used, it is closely connected with the transmission roller of the composite paper production equipment. The encoder records the corresponding pulse signal every time the transmission roller rotates one circle. Through counting the pulse signal and the preset transmission roller circumference parameter, the length of the paper movement, that is, the unit variable composite paper length ΔX, can be accurately calculated. If a photoelectric sensor is selected, the distance of the paper movement is accurately measured according to the changes of the shielding or reflection of the light in the paper movement process by using the principle of emitting and receiving light, and ΔX is obtained.

[0059] The scale in the sensor module monitors the usage of glue, varnish and back coating liquid in real time. Taking an electronic scale as an example, the container containing the coating material is placed on the weighing platform. As the coating material is consumed in the production process, the scale can sense the weight change in real time, and transmit the measurement data to the data processing unit in the form of an electric signal. If a liquid level sensor is also provided in the sensor module, the liquid level sensor is installed in the coating material storage container, and the coating material usage is measured by monitoring the change of the liquid level, which is complementary to the scale data to improve the measurement accuracy.

[0060] The data processing unit starts data processing work after receiving ΔX collected by the detection module, Y and Z input by the input module, and ΔL transmitted by the sensor module 胶水 , ΔL 清漆 , and ΔL 背涂液 data. If the data processing unit uses a programmable logic controller (PLC), it will call the internal stored calculation formula according to the pre-written program to process these data. For example, according to the glue load calculation formula U1 胶水 = 10 6 × ΔL 胶水 / (ΔX × Y), the glue load per unit area of the composite paper is calculated. If a single-chip microcomputer such as an ARM Cortex-M4 microcontroller is used, it will convert the analog signal transmitted by the sensor module into a digital signal through the SPI interface connected analog-to-digital converter (ADC), and then combine the detection module pulse signal obtained through the GPIO interface to perform data processing and calculation.

[0061] The calculated coating material load data per unit area of the composite paper is transmitted to the display module in real time. If the display module uses a liquid crystal display (LCD), it will clearly display the specific values of the glue load U1 胶水 , varnish load U2 清漆 , and back coating liquid load U3 背涂液 . At the same time, the display module will also display the trend of these data over time in the form of a chart, such as drawing a line chart, so that the operator can intuitively observe the fluctuation of the data and judge whether the production process is stable.

[0062] During production, the data processing unit compares the calculated coating material load data with the preset threshold range. These threshold ranges are stored in the EEPROM memory built-in the data processing unit and will be dynamically loaded according to different product types. When the data exceeds the preset range, the data processing unit will send a signal to the warning module. After receiving the signal, the warning module will issue an alarm through sound alarm and light flashing, reminding the operator to take timely measures to adjust the production parameters.

[0063] The storage module will continuously store the calculated coating material load data per unit area of the composite paper. The storage duration is not less than 1 year, providing data resources for subsequent data analysis and production optimization. Enterprises can regularly analyze the stored data, summarize the production law, and find out potential problems in the production process, such as analyzing the trend of coating material consumption in different time periods to judge whether the production equipment has abnormal wear or other problems.

[0064] The communication module transmits the coating material loading data per unit area of the composite paper to a remote server. If the communication module supports 4G or 5G wireless communication network, it will quickly and stably transmit data to the remote server in a wireless manner. The management personnel of the enterprise can access the remote server at any time and anywhere through mobile phones, computers and other terminal devices to view production data and analyze production trends. The remote server can also conduct in-depth mining and analysis on a large amount of production data. For example, through big data analysis technology, the key factors affecting product quality can be found out to provide strong support for the production decision of the enterprise.

[0065] In some special production scenarios, if it is necessary to measure the amount of each coating material more accurately, multiple independent weighing units in the sensor module will weigh the glue tank, varnish tank and back coating liquid tank respectively. Each independent weighing unit can monitor the weight change of the coating material in the corresponding tank in real time and accurately, avoiding the mutual interference between different coating materials and further improving the measurement accuracy. At the same time, the temperature sensor in the sensor module will monitor the environmental temperature in real time and transmit the temperature data to the data processing unit. The data processing unit will perform temperature compensation calculation on ΔL 胶水 , ΔL 清漆 or ΔL 背涂液 according to the preset temperature compensation algorithm to eliminate the influence of temperature factors on the measurement results and ensure the accuracy of the measurement data.

[0066] In terms of coating material supply, the multi-channel electromagnetic valve group in the sensor module plays a key role. It will accurately control the supply pipeline of glue, varnish and back coating liquid according to the instruction of the data processing unit. For example, when the data processing unit detects that the glue loading on the unit area of the composite paper is lower than the preset standard, it will send a signal to the multi-channel electromagnetic valve group. After receiving the signal, the multi-channel electromagnetic valve group will appropriately increase the supply amount of glue to ensure the stability of the coating material usage and the consistency of the product quality in the production process.

[0067] In terms of daily maintenance and management of the equipment, the modular design of each module makes the maintenance work more convenient. When a module fails, the technician can quickly determine the faulty module and carry out targeted repair or replacement. For example, if the display module has display abnormalities, the technician can directly disassemble it from the protective cabinet for inspection and repair without affecting the normal work of other modules. At the same time, the modular design also facilitates the upgrading and expansion of the equipment. With the continuous development of technology and the change of production needs, the enterprise can upgrade some modules according to the actual situation, such as replacing higher precision sensor modules or adding new functional modules, such as adding a gas detection module to monitor the concentration of harmful gases in the production environment to meet more stringent production requirements.

[0068] The device can play an important role in composite paper production enterprises of different scales. For small enterprises, the low cost and easy operability of the device can help them quickly realize data management of the production process, improve product quality, and enhance market competitiveness. Small enterprises can choose a more basic configuration according to their production needs, such as using a single-chip microcomputer as a data processing unit, and matching a simple display module and a warning module to realize monitoring and control of key production data. For large enterprises, the scalability and remote management functions of the device are particularly important. Large enterprises usually have multiple production workshops and complex production processes. Through the communication module of the device, the data of each workshop is aggregated to a remote server, and the enterprise management layer can conduct centralized management and analysis. At the same time, large enterprises can select higher-performance equipment components according to production scale and precision requirements, such as high-precision electronic scales and powerful programmable logic controllers (PLC), to ensure efficient and stable operation of the production process.

[0069] In terms of cooperation with other production equipment, the device also has good compatibility. It can interact with and cooperatively control other equipment on the composite paper production line, such as coaters and printers. For example, when the device detects that the glue load per unit area of paper is too high, it can send a signal to the coater to automatically adjust the coating parameters of the coater to reduce the amount of glue applied, achieving automated and intelligent control of the entire production process. Through cooperation with other equipment, production efficiency is improved, and product quality stability is further ensured.

[0070] In addition, the device has certain positive significance in energy saving and environmental protection. By monitoring and accurately controlling the amount of coating material used, enterprises can avoid waste caused by excessive use of coating materials, reducing production costs while reducing environmental pollution. For example, in traditional production methods, due to the inability to accurately control the amount of coating material used, some coating materials may not be fully utilized and volatilize into the environment, causing resource waste and environmental pollution. The device can accurately control the amount of coating material used, improve the utilization rate of coating materials, and achieve green production.

[0071] The various exemplary embodiments of the present application will be further illustrated by the following list of embodiments, which should not be construed as unduly limiting the present application:

[0072] Specific embodiment 1 is a coating material load real-time monitoring device for composite paper production, characterized by comprising:

[0073] a detection module, the detection module comprising an encoder or a photoelectric sensor for real-time acquisition of the variable length ΔX of the paper in the composite paper production process;

[0074] an input module for manually inputting a film width Y of a composite film and a web width Z of the paper after being laminated with the composite film;

[0075] a sensor module comprising a scale for measuring the amount of glue, varnish and back-coating liquid ΔL used when producing a certain length of the composite paper, and transmitting data to a data processing unit; 胶水 , ΔL 清漆 and ΔL 背涂液 ;

[0076] a data processing unit connected with the detection module, the input module and the sensor module and comprising a programmable logic controller for calculating the coating material loading of the composite paper per unit area according to the following formula:

[0077] a glue loading U1 胶水 = 10 6 × ΔL 胶水 / (ΔX × Y), unit: g / m 2 ;

[0078] a varnish loading U2 清漆 = 10 6 × ΔL 清漆 / (ΔX × Z), unit: g / m 2 ; or

[0079] a back-coating liquid loading U3 背涂液 = 10 6 × ΔL 背涂液 / (ΔX × Z), unit: g / m 2 .

[0080] Embodiment 2 is the coating material loading real-time monitoring device for composite paper production according to Embodiment 1, characterized in that the detection module comprises an encoder or a photoelectric sensor.

[0081] Embodiment 3 is the coating material loading real-time monitoring device for composite paper production according to Embodiment 2, characterized in that the encoder is connected with a transmission roller of a composite paper production equipment to collect the variable length ΔX of the paper.

[0082] Embodiment 4 is the coating material loading real-time monitoring device for composite paper production according to Embodiment 2, characterized in that the photoelectric sensor acquires the variable length ΔX of the paper by measuring the distance of the paper movement.

[0083] Specific implementation 5 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the input module is a touch screen input module, supporting the operator to directly input the film width Y of the composite film and the width Z of the paper after being attached to the composite film on the screen.

[0084] Specific implementation 6 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the input module is a keyboard input module, equipped with a digital keyboard so that the operator can input the film width Y of the composite film and the width Z of the paper after being attached to the composite film.

[0085] Specific implementation 7 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the scale in the sensor module is an electronic scale with a measurement accuracy of ±0.1g.

[0086] Specific implementation 8 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the scale in the sensor module has a data storage function and can store at least 1000 groups of measurement data.

[0087] Specific implementation 9 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the sensor module includes a liquid level sensor in addition to the scale, which is used to assist in monitoring the usage of the glue, the varnish and the back coating liquid.

[0088] Specific implementation 10 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the sensor module and the data processing unit are connected through a wired Ethernet interface for data transmission.

[0089] Specific implementation 11 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the sensor module and the data processing unit are connected through a wireless Bluetooth interface for data transmission.

[0090] Specific implementation 12 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the data processing unit is a programmable logic controller (PLC) with stable data processing capability.

[0091] Specific implementation 13 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the data processing unit is a single-chip microcomputer with the characteristics of low power consumption and high integration.

[0092] Specific implementation 14 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the device further comprises a display module connected with the data processing unit, for displaying the glue loading U1 of the composite paper per unit area in real time 胶水 , varnish loading U2 清漆 , and back coating liquid loading U2 背涂液 .

[0093] Specific implementation 15 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 14, characterized in that the display module is a liquid crystal display (LCD) that can clearly display various data.

[0094] Specific implementation 16 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 14, characterized in that the display module can display the trend of the coating material loading of the composite paper per unit area over time in the form of a chart.

[0095] Specific implementation 17 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the device further comprises a warning module connected with the data processing unit, which sends an alarm when the coating material loading of the composite paper per unit area exceeds the preset normal range.

[0096] Specific implementation 18 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 17, characterized in that the alarm mode of the warning module includes sound alarm and light flashing alarm.

[0097] Specific implementation 19 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the device further comprises a storage module connected with the data processing unit, for storing the calculated coating material loading data of the composite paper per unit area, with a storage duration of not less than 1 year.

[0098] Specific implementation 20 is the coating material loading real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the device further comprises a communication module connected with the data processing unit, which can transmit the coating material loading data of the composite paper per unit area to a remote server for data analysis and management.

[0099] Specific implementation 21 is the coating material load real-time monitoring device for composite paper production according to specific implementation 20, characterized in that the communication module supports a 4G or 5G wireless communication network.

[0100] Specific implementation 22 is the coating material load real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the sensor module includes a plurality of independent weighing units respectively located below the glue storage tank, the varnish storage tank and the back coating liquid storage tank.

[0101] Specific implementation 23 is the coating material load real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the sensor module further includes a temperature sensor for monitoring the ambient temperature and performing temperature compensation calculation on ΔL 胶水 , ΔL 清漆 or ΔL 背涂液 by the data processing unit.

[0102] Specific implementation 24 is the coating material load real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the detection module includes an optical encoder installed at the shaft end of the composite paper roll, which converts the length change amount ΔX of the composite paper into the number of rotations by pulse signal counting.

[0103] Specific implementation 25 is the coating material load real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the sensor module further includes a multi-channel electromagnetic valve group for respectively controlling the glue, varnish and back coating liquid supply pipelines.

[0104] Specific implementation 26 is the coating material load real-time monitoring device for composite paper production according to specific implementation 22, characterized in that the scale of the sensor module is a cantilever beam type weighing sensor installed on the support frame of the glue storage tank, the varnish storage tank and the back coating liquid storage tank, and the weighing sensor outputs the weight signal to the data processing unit through a Wheatstone bridge circuit.

[0105] Specific implementation 27 is the coating material load real-time monitoring device for composite paper production according to specific implementation 1, characterized in that the data processing unit includes an ARM Cortex-M4 microcontroller connected to an analog-to-digital converter (ADC) through an SPI interface for receiving analog signals from the sensor module, and connected to the pulse signal of the detection module through a GPIO interface.

[0106] Specific implementation solution 28 is the coating material loading real-time monitoring device for composite paper production according to the specific implementation solution 1, characterized in that the data processing unit is embedded with EEPROM memory for storing the preset threshold value range of U1 胶水 , U2 清漆 and U3 背涂液 , which is dynamically loaded according to the product type.

[0107] The coating material loading real-time monitoring device for composite paper production according to the present application has the following advantages:

[0108] 1. The detection module, sensor module and data processing unit cooperate to collect and calculate the glue amount, varnish amount and back coating amount on the unit area of paper in real time. Compared with traditional manual measurement and calculation, the timeliness and accuracy are greatly improved, and the change of coating material usage can be quickly detected to provide basis for production adjustment. For example, the traditional method needs to measure and calculate after a certain length of production, while the device can obtain data in real time.

[0109] 2. The display module intuitively presents the coating material loading data and displays the data change trend in a chart, which is convenient for operators to record and track product data, provides intuitive and scientific basis for production management, and is convenient for judging production stability and adjusting production parameters.

[0110] 3. The early warning module timely alarms when the coating material loading exceeds the preset range, reminding the operator to adjust, effectively avoiding quality problems such as aluminum and ink explosion, sticking flowers and paper deformation caused by improper coating material usage, and ensuring product quality stability. For example, when the glue loading is abnormal, timely adjustment can be reminded to improve product pass rate.

[0111] 4. The storage module long-term saves production data to provide data support for enterprise analysis and process optimization; the communication module realizes remote data transmission, which is convenient for remote monitoring and centralized management. Enterprises can analyze and optimize production and improve management level through remote server aggregation.

[0112] 5. The modules cooperate with each other to form a complete production monitoring and management system. The diversified design makes the device adapt to different production environments and needs, such as multiple collection methods of the detection module, multiple input methods of the input module, multiple selections of the data processing unit, etc., which improves the practicality and adaptability and ensures the good operation of the device on different equipment.

[0113] 6. The modules are designed in a modular way, so that technicians can quickly determine and repair or replace the faulty module when a fault occurs, without affecting the work of other modules. At the same time, it is convenient for equipment upgrading and expansion. According to the technical development and production demand, some modules can be upgraded or new modules can be added to meet more stringent production requirements.

[0114] 7. The production data of the storage module can be used for product quality traceability, quickly locate the cause when problems occur, solve customer problems and improve production processes. In addition, the device can interact and cooperatively control data with other equipment on the production line, realize automatic and intelligent production, improve production efficiency and product quality stability.

[0115] 8. Real-time monitoring and precise control of the amount of coating material, avoiding waste caused by excessive use, reducing production costs, reducing environmental pollution, improving the utilization rate of coating materials, and realizing green production.

[0116] Obviously, those skilled in the art can make various modifications and variations to the present disclosure without departing from the spirit and scope of the present disclosure. Thus, if these modifications and variations of the present disclosure fall within the scope of the claims of the present utility model and their equivalents, the present disclosure also intends to include these modifications and variations.

Claims

1. A real-time monitoring device for coating material load in composite paper production, characterized in that, include: The detection module includes an encoder or a photoelectric sensor for real-time acquisition of the variable length ΔX of the paper during the composite paper production process. An input module is used to manually input the film width Y of the composite film and the width Z of the paper after the composite film is applied. The sensor module includes a weighing scale used to measure the amount ΔL of glue, varnish, and backing liquid used in the production of a certain length of the composite paper. 胶水 ΔL 清漆 and ΔL 背涂液 and transmit the data to the data processing unit; A data processing unit, connected to the detection module, the input module, and the sensor module, and including a programmable logic controller (PLC), is configured to calculate the coating material load per unit area of ​​the composite paper according to the following formula: Adhesive load U1 胶水 =10 6 ×ΔL 胶水 / (ΔX×Y), in g / m 2 ; Clear coat load U2 清漆 =10 6 ×ΔL 清漆 / (ΔX×Z), in g / m 2 ; or Back coating liquid loading U3 背涂液 =10 6 ×ΔL 背涂液 / (ΔX×Z), in g / m 2 .

2. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that, The encoder is connected to the drive roller of the composite paper production equipment to collect the variable length ΔX of the paper.

3. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that, The photoelectric sensor obtains the variable length ΔX of the paper by measuring the distance the paper moves.

4. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that: The input module is a touchscreen input module, which allows operators to directly input the film width Y of the composite film and the width Z of the paper after the composite film is applied onto the screen, or The input module is a keyboard input module, equipped with a numeric keypad so that the operator can input the film width Y of the composite film and the width Z of the paper after the composite film is applied.

5. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that, In addition to the scale, the sensor module also includes a liquid level sensor to assist in monitoring the amount of adhesive, varnish and back coating liquid used.

6. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that, The data processing unit is a programmable logic controller or a microcontroller.

7. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that, The device further includes a display module connected to the data processing unit, which is used to display the adhesive load U1 per unit area of ​​the composite paper in real time. 胶水 , Clear coat load U2 清漆 and back coating liquid loading U2 背涂液 .

8. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that, The device also includes an early warning module connected to the data processing unit. When the coating material load per unit area of ​​the composite paper exceeds a preset normal range, the early warning module issues an alarm.

9. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that: The device further includes a storage module connected to the data processing unit; and / or The device also includes a communication module, which is connected to the data processing unit.

10. The real-time monitoring device for coating material load in composite paper production according to claim 1, characterized in that, The sensor module includes multiple independent weighing units, which are located below the glue storage tank, varnish storage tank and back coating liquid storage tank of the composite paper production equipment.

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