A material shortage alarm device for an extruder based on photoelectric induction

Abstract

This utility model belongs to the technical field of plastic extrusion equipment, and provides a material shortage alarm device for extruders based on photoelectric sensing. It includes a photoelectric sensing module comprising an infrared transmitter and a receiver installed on both sides of the feed inlet of the extruder hopper. The receiver detects changes in light intensity emitted by the infrared transmitter and converts them into electrical signals. At least one of the infrared transmitter and the receiver is inclined. Compared with existing technologies, the advantages of this utility model are that it uses non-contact photoelectric detection technology to avoid the problems of traditional mechanical wear, and the inclined installation facilitates the natural descent of materials by gravity, reducing blind spots. Combined with an external high-temperature resistant transparent protective cover with an anti-stick coating to prevent molten plastic from adhering and affecting light transmittance, the complementary structure of these two components improves the stability, environmental adaptability, and flexibility of the device's installation structure.

Description

Technical Field

[0001] This utility model belongs to the technical field of plastic extrusion equipment, specifically relating to a material shortage alarm device for extruders based on photoelectric sensing. Background Technology

[0002] Extruders play a crucial role in the production of plastic products. However, in actual operation, insufficient feeding or material shortages can severely affect product quality and even lead to equipment damage. To effectively monitor and prevent these problems, existing technologies typically employ rotary paddle level switches or rely on manual inspections to detect material shortages. While these methods are effective to some extent, they generally have some significant limitations:

[0003] 1. Low sensitivity: Rotary paddle level switches detect the presence of material by moving mechanical parts. This method is slow to react to slight changes in material and cannot detect the initial material shortage in time, thus delaying the best time to take corrective measures.

[0004] 2. Susceptible to interference from material adhesion: Especially when handling sticky plastic raw materials, the material can easily adhere to the sensor surface, affecting its normal operation and leading to false alarms or missed alarms. This not only reduces production efficiency but may also cause unnecessary downtime for maintenance.

[0005] 3. Limitations of manual inspection: Although manual inspection can make up for the shortcomings of the above technologies to some extent, this method is highly dependent on the experience and sense of responsibility of the operators, and it is difficult to achieve real-time monitoring of the production process. Especially in large-scale, continuous production environments, the frequency and coverage of manual inspection are often limited. Utility Model Content

[0006] The purpose of this invention is to address the aforementioned problems in the existing technology by proposing a photoelectric sensing-based extruder material shortage alarm device that is simple in structure, highly reliable, reduces blind spot obstruction, and has high temperature resistance and automatic cleaning functions.

[0007] The purpose of this utility model can be achieved through the following technical solution: a photoelectric sensing-based extruder material shortage alarm device is proposed, comprising: a photoelectric sensing module, including an infrared transmitter and a receiver installed on both sides of the feed inlet of the extruder hopper, wherein the receiver is used to detect the light intensity change emitted by the infrared transmitter and convert it into an electrical signal, wherein at least one of the infrared transmitter and the receiver is tilted, and there is a height difference when both the infrared transmitter and the receiver are tilted;

[0008] A transparent protective cover is provided on both the infrared transmitter and the receiver. The transparent protective cover is used to enhance the adaptability to the material shortage detection environment.

[0009] The system includes a signal processing module and an alarm module. The signal processing module compares the received electrical signal with a material shortage threshold and sends a stop command through the alarm module.

[0010] The linkage control module is connected to the main control system of the extruder and is used to automatically reduce the screw speed or stop the extruder when there is a shortage of material, so as to prevent idling losses.

[0011] In the above-mentioned photoelectric sensing-based extruder material shortage alarm device, mounting brackets are provided on both sides of the feed inlet, and the infrared transmitter and the receiver can be detachably connected to the mounting brackets.

[0012] In the above-mentioned extruder material shortage alarm device based on photoelectric sensing, the mounting bracket is provided with an inclined mounting surface, and the infrared transmitter and the receiver are both disposed on the inclined mounting surface.

[0013] In the above-mentioned extruder material shortage alarm device based on photoelectric sensing, the mounting bracket is provided with an adjusting component, which is used to adjust the distance between the infrared transmitter and the receiver.

[0014] In the aforementioned photoelectric sensing-based extruder material shortage alarm device, a cleaning air pump for removing dust is installed inside the transparent protective cover.

[0015] In the above-mentioned photoelectric sensing-based extruder material shortage alarm device, the angle between the inclined mounting surface and the vertical direction is 30°.

[0016] In the above-mentioned photoelectric sensing-based extruder material shortage alarm device, the surface of the transparent protective cover is coated with an anti-stick coating to prevent molten plastic from adhering to the transparent protective cover.

[0017] In the above-mentioned extruder material shortage alarm device based on photoelectric sensing, the signal processing module integrates a PLC or a microcontroller to receive photoelectric signals and output alarm commands.

[0018] In the above-mentioned extruder material shortage alarm device based on photoelectric sensing, the alarm module is an audible and visual alarm or a remote wireless transmission module. The audible and visual alarm consists of a buzzer and an LED flashing light, and is used for centralized monitoring of multiple machines in the workshop.

[0019] The aforementioned photoelectric sensing-based extruder material shortage alarm device also includes a channel redundancy detection module.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] (1) The present invention provides a material shortage alarm device for extruders based on photoelectric sensing. It adopts non-contact photoelectric detection technology to avoid the problem of traditional mechanical wear. The inclined installation facilitates the natural falling of materials by gravity, reducing blind spots. It is equipped with a high-temperature resistant transparent protective cover with an anti-stick coating on its surface to prevent the plastic melt from adhering and affecting the light transmittance. The two structures complement each other, improving the stability of the installation structure, environmental adaptability and flexibility of the device.

[0022] (2) The distance between the infrared transmitter and receiver can be quickly adjusted by adjusting the adjustment component to adapt to materials of different particle sizes processed by the extruder hopper, thereby improving the flexibility and applicability of the device.

[0023] (3) By integrating a cleaning air pump inside the transparent protective cover, compressed air is sprayed regularly to remove dust, so as to avoid the infrared transmitter and receiver being affected by dust or impurities and ensure smooth reception of light. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of this application;

[0025] Figure 2 yes Figure 1 A magnified view of section A in the image.

[0026] In the diagram, 1 is the photoelectric sensing module; 10 is the infrared transmitter; 11 is the receiver; 12 is the power supply; 2 is the signal processing module; 3 is the alarm module; 30 is the buzzer; 31 is the LED flashing light; 4 is the extruder hopper; 40 is the feed inlet; 400 is the mounting bracket; 400a is the inclined mounting surface; 41 is the suction feeder; and 42 is the material. Detailed Implementation

[0027] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings to further illustrate the technical solutions of the present invention. However, the present invention is not limited to these embodiments.

[0028] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0029] like Figures 1 to 2 As shown, this utility model discloses a material shortage alarm device for an extruder based on photoelectric sensing, which includes a photoelectric sensing module 1, a transparent protective cover, a signal processing module 2, an alarm module 3, and a linkage control module.

[0030] The photoelectric sensing module 1 includes an infrared transmitter 10 and a receiver 11 (each equipped with a power supply 12) installed on both sides of the feed inlet 40 of the extruder hopper 4. The receiver 11 is used to detect changes in the light intensity emitted by the infrared transmitter 10 and convert them into electrical signals. At least one of the infrared transmitter 10 and the receiver 11 is tilted, and there is a height difference when both the infrared transmitter 10 and the receiver 11 are tilted. Both the infrared transmitter 10 and the receiver 11 are equipped with transparent protective covers to enhance the adaptability of the material shortage detection environment. The signal processing module 2 is used to compare the received electrical signals with the material shortage threshold and send a stop command through the alarm module 3. The linkage control module is connected to the main control system of the extruder and is used to automatically reduce the screw speed or stop the extruder when there is a material shortage to prevent idling losses.

[0031] Specifically, such as Figure 1As shown, during the extrusion machine production process, insufficient feeding or material interruption can lead to defects in the extruded products or even damage to the equipment. To solve the above technical problems, in this embodiment, an infrared transmitter 10 is installed on one side of the feed inlet 40 of the extruder hopper 4, and a receiver 11 is installed on the other side. When the material 42 is supplied normally (the material 42 is sent into the extruder hopper 4 by the suction feeder 41), the material 42 will block the infrared beam, thereby determining the continuous flow of the material 42. As the receiver 11 converts the received infrared light intensity into a corresponding electrical signal, it is transmitted to the signal processing module 2. The signal processing module 2 has a built-in material shortage threshold judgment mechanism (not shown in the figure). When the infrared signal is lower than the set threshold for a long time (e.g., the light intensity is lower than the set value for 5 seconds and is judged as material shortage), it is judged as a material shortage state, and an alarm command is immediately output. Once the material shortage is confirmed, the signal processing module 2 immediately triggers the alarm module 3 to issue an audible and visual alarm to remind the operator. At the same time, the linkage control module communicates with the extruder main control system to automatically reduce the screw speed or stop the machine directly to prevent the equipment from running idle, which would cause energy waste and mechanical wear. It is worth noting that the infrared transmitter 10 and receiver 11 in this embodiment are installed in three ways: one is by installing the receiver 11 at an angle, another is by installing the infrared transmitter 10 at an angle, and the last is by installing both the infrared transmitter 10 and receiver 11 at an angle. It should be noted that under these three angled installation methods, the receiver 11's reception of the infrared light source is not affected (this is also the purpose of the aforementioned height difference design). This angled design allows the material 42 to fall naturally using gravity, preventing the appearance of blind spots that could affect the accuracy of detection. Meanwhile, this embodiment also provides transparent protective covers on the outside of both the infrared transmitter 10 and receiver 11, which can effectively block dust, moisture, and other impurities from entering the sensor, avoiding false alarms or missed alarms. These covers also have certain corrosion resistance and explosion-proof properties, maintaining good detection performance even in dusty, high-temperature, and high-humidity conditions, thus extending the equipment's service life. Therefore, with the complementary effects of the inclined installation design and the transparent protective cover structure, the device can monitor the material status in real time and provide timely warnings of material shortages. This helps operators respond quickly and avoids product quality problems caused by material shortages. The reasonable structural design greatly improves the stability and environmental adaptability of the device.

[0032] Mounting brackets 400 are provided on both sides of the feed inlet 40, and the infrared transmitter 10 and receiver 11 can be detachably connected to the mounting brackets 400.

[0033] Furthermore, such as Figure 1 and Figure 2As shown, in this embodiment, through holes are provided on both sides of the feed inlet 40. The mounting bracket 400 can be fixed to the side wall by screws, bolts and other components. The detachable connection structure greatly improves the maintainability of the device. Operators can quickly replace faulty sensors. At the same time, the sensors can be easily removed for dust removal during the cleaning cycle, ensuring detection stability during long-term operation and reducing manufacturing and maintenance costs.

[0034] The mounting bracket 400 has an inclined mounting surface 400a, and the infrared transmitter 10 and receiver 11 are both mounted on the inclined mounting surface 400a.

[0035] like Figure 1 and Figure 2 As shown, to achieve the aforementioned tilted installation, this embodiment features a tilted mounting surface 400a on the mounting bracket 400. This design helps prevent dust accumulation on the sensor surface, and the detachable structure facilitates regular cleaning and sensor replacement. Furthermore, the mounting bracket 400 serves as a calibration reference, ensuring that the infrared transmitter 10 and receiver 11 maintain optimal alignment. Therefore, this tilted installation helps avoid interference from mechanical components, dust concentration areas, or heat sources near the feed inlet 40; reduces detection errors caused by external factors (such as vibration, oil, and high temperatures); and improves the applicability of the device in complex industrial environments.

[0036] Preferably, in this embodiment, the photoelectric sensing modules 1 are all installed at an angle of 30 degrees. That is, the angle between the inclined mounting surface 400a and the vertical direction is 30° (i.e., the infrared transmitter 10 and the receiver 11 are close to the inclined mounting surface 400a). The 30° tilt angle design can effectively avoid the central area of ​​the material 42 falling naturally without affecting the infrared signal transmission and reception, reduce the blind spot, and prevent false alarms. For particles with larger particle sizes, this angle can also ensure that the beam will not be frequently and briefly blocked, thus affecting the judgment.

[0037] More preferably, this embodiment also includes an adjusting component (not shown in the figure) on the mounting bracket 400. It should be noted that the adjusting component can be a screw or other component that passes through the mounting bracket 400 and connects the infrared transmitter 10 and the receiver 11. Under the adjustment of the threaded engagement, the distance between the infrared transmitter 10 and the receiver 11 can be effectively adjusted. As a result, this structure can flexibly adjust the distance between the transmitter and the receiver 11 according to different models of extruders and different types of materials 42. A reasonable distance setting can avoid misjudgment caused by the material 42 particles being too large or too small. For fine powder materials 42, reducing the distance can improve the detection sensitivity; for large particles of material 42, increasing the distance can reduce interference and improve the judgment accuracy. When used in conjunction with the inclined mounting surface 400a, it can further avoid dust concentration areas or mechanical interference areas, improving the accuracy and stability of the device during detection.

[0038] More preferably, this embodiment also includes a cleaning air pump (not shown in the figure, this cleaning air pump is a miniature air pump) installed inside the transparent protective cover for removing dust. This cleans the sensor surface periodically or as needed, ensuring a clear and unobstructed infrared beam transmission path and preventing false alarms or missed alarms caused by dust accumulation. This improves the long-term operational stability of the entire device, which is particularly important in dusty industrial environments. Preferably, the transparent protective cover in this embodiment is made of a high-temperature resistant material, with the material model referring to Plexiglas Resist 120.

[0039] More preferably, this embodiment also has an anti-stick coating (not shown in the figure) deposited on the surface of the transparent protective cover. This anti-stick coating prevents contaminants such as plastic melt and dust from adhering to the surface of the protective cover, avoids misjudgment caused by obstruction of the light path, improves the transmittance of the infrared beam, and enhances the system's ability to identify the flow state of the material 42. It is particularly suitable for extrusion processing environments with high temperature, high dust, and easy generation of splashed melt.

[0040] In this embodiment, the signal processing module 2 integrates a PLC or a microcontroller (choose one), which can quickly and accurately process complex photoelectric signals, reduce the false judgment rate, and ensure that an alarm is only issued when there is a real shortage of materials. By learning and analyzing historical data, the alarm threshold settings can be continuously optimized to further improve the reliability of the system.

[0041] In this embodiment, the alarm module 3 includes an audible and visual alarm or a remote wireless transmission module (optional). The audible and visual alarm combines auditory and visual stimulation to ensure that operators can quickly detect abnormalities even in noisy environments. The combination of the buzzer 30 and the LED flashing light 31 in the audible and visual alarm is low-cost and highly reliable, and is used for centralized monitoring of multiple machines in the workshop. It is also suitable for various industrial environments.

[0042] Finally, this embodiment also employs a channel redundancy detection module (not shown in the figure). Channel redundancy detection is a method to improve system reliability by using two independent sensors and logical judgments. It is widely used in industrial automation, safety control, material detection, and other fields. This design is the same as the detection method and principle used in the prior art, and will not be described in detail here. Its core objective is to reduce the false alarm rate and the false alarm rate, and to ensure that the system can still work stably when the sensor fails or there is environmental interference.

[0043] It should be noted that in this invention, the use of terms such as "first," "second," and "a" is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified. The terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two elements or the interaction between two elements, unless otherwise explicitly specified. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0044] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

[0045] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A photoelectrically sensing based material shortage alarm device for an extruder, characterized by, include: The photoelectric sensing module includes an infrared transmitter and a receiver installed on both sides of the feed inlet of the extruder hopper. The receiver is used to detect changes in light intensity emitted by the infrared transmitter and convert them into electrical signals. At least one of the infrared transmitter and the receiver is tilted, and there is a height difference when both the infrared transmitter and the receiver are tilted. A transparent protective cover is provided on both the infrared transmitter and the receiver. The transparent protective cover is used to enhance the adaptability to the material shortage detection environment. The system includes a signal processing module and an alarm module. The signal processing module compares the received electrical signal with a material shortage threshold and sends a stop command through the alarm module. The linkage control module is connected to the main control system of the extruder and is used to automatically reduce the screw speed or stop the extruder when there is a shortage of material, so as to prevent idling losses.

2. A photoelectrically induced material deficiency alarm device for an extruder as set forth in claim 1, characterized in that, Mounting brackets are provided on both sides of the feed inlet, and both the infrared transmitter and the receiver can be detachably connected to the mounting brackets.

3. A photoelectrically induced material deficiency alarm device for an extruder as defined in claim 2, characterized in that The mounting bracket is provided with an inclined mounting surface, and both the infrared transmitter and the receiver are mounted on the inclined mounting surface.

4. A photoelectrically induced material deficiency alarm device for an extruder as defined in claim 2, wherein The mounting bracket is provided with an adjustment component, which is used to adjust the distance between the infrared transmitter and the receiver.

5. A photoelectrically induced material deficiency alarm device for an extruder as defined in claim 1, wherein The transparent protective cover is equipped with a cleaning air pump for removing dust.

6. A photoelectrically induced material deficiency alarm device for an extruder as defined in claim 3, wherein The angle between the inclined mounting surface and the vertical direction is 30°.

7. A photoelectrically induced material deficiency alarm device for an extruder as defined in claim 6, wherein The surface of the transparent protective cover is coated with an anti-stick coating to prevent molten plastic from adhering to the transparent protective cover.

8. A photoelectric sensing-based extruder material shortage alarm device according to claim 1, characterized in that, The signal processing module integrates a PLC or a microcontroller to receive photoelectric signals and output alarm commands.

9. A photoelectric sensing-based extruder material shortage alarm device according to claim 1, characterized in that, The alarm module is either an audible and visual alarm or a remote wireless transmission module. The audible and visual alarm consists of a buzzer and an LED flashing light and is used for centralized monitoring of multiple machines in the workshop.

10. A photoelectric sensing-based extruder material shortage alarm device according to claim 1, characterized in that, It also includes a channel redundancy detection module.

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