Temperature synchronization detection device

Abstract

This utility model relates to the technical field of polyurethane product manufacturing equipment, specifically to a temperature synchronization detection device. It includes a first temperature sensor for detecting the external temperature, denoted as Ta, and a heating furnace temperature, denoted as Tb. Ta and Tb are inversely proportional. A second temperature sensor is installed on the mold for detecting the mold temperature, denoted as Tm. The fluctuating temperature difference, denoted as ΔT, is calculated using the formula Tm - [59 + 0.5 × (Ta - 40)]. If |ΔT| > 1℃, the steam flow rate setting of the heating furnace is corrected. This utility model ensures that the temperature at the mold is always greater than 59℃, and that the mold temperature stability remains within ±1℃ when the external air temperature fluctuates within the range of -5℃ to 40℃. This improves the consistency of production throughout the four seasons and reduces the steam consumption of the heating furnace by 12%, thus lowering operating costs.

Description

Technical Field

[0001] This utility model relates to the technical field of polyurethane product manufacturing equipment, specifically to a temperature synchronization detection device. Background Technology

[0002] In the production of polyurethane products such as foam cushions, the trolley mold needs to be heated to above 59°C in a steam furnace to ensure product rigidity. However, existing technologies have many shortcomings:

[0003] 1. Lack of closed-loop temperature control

[0004] The heating furnace uses a wind-circulating steam heat exchanger, and a fixed temperature value is set locally via a temperature controller (with PID calculation). It cannot dynamically adjust the steam flow based on the real-time temperature of the mold on the trolley. When the actual temperature of the mold deviates from the target value, the system lacks an automatic compensation mechanism, resulting in insufficient heating or excessive energy consumption.

[0005] 2. Challenges in Temperature Detection on Mobile Trolleys

[0006] The trolley moves continuously along a circular trajectory. Traditional fixed detection points or handheld devices cannot achieve synchronous data acquisition with the moving mold. Temperature sampling has a time difference of ±15 seconds, and the docking position deviation between the sensor and the mold is ±10mm, resulting in low measurement accuracy (error >3℃).

[0007] 3. Significant interference from the external atmospheric environment.

[0008] The heating furnace temperature control is not interlocked with the outside air temperature. Every ±5℃ fluctuation in the ambient temperature will cause the actual mold temperature to deviate by ±2.5℃. Especially in winter when the temperature difference between day and night is large, the product defect rate fluctuates by up to 8%.

[0009] 4. Delayed response to abnormalities

[0010] When the mold temperature is below the threshold (59℃), the decision to stop the robot injection is made manually, which has a decision delay of more than 30 seconds and produces about 5 to 8 defective products per shift. In addition, there is no automatic alarm mechanism, and abnormal conditions are difficult to detect in time.

[0011] 5. Low system integration

[0012] Temperature data needs to be manually recorded and then imported into the control system. It cannot be directly linked to the heating furnace adjustment and material injection path control, forming an information silo of "detection-control-execution" and resulting in low production efficiency.

[0013] In addition, in existing technologies, non-contact infrared detection has an error of >4°C due to the difference in reflectivity of oil stains on the mold surface, while wired transmission solutions are prone to cable wear due to the limitations of trolley movement. Neither of these can meet the production requirements of high precision and high dynamics. Utility Model Content

[0014] To address the aforementioned issues, a temperature synchronization detection device is provided. This device is used to detect the temperature of the mold on the trolley, and a heating furnace that uses steam to heat the mold is installed on one side of the mold.

[0015] The synchronous detection device includes a first temperature sensor, which is set on one side of the heating furnace and used to detect the external temperature. The detected value is Ta. A third temperature sensor is set inside the heating furnace to detect the temperature inside the heating furnace. The temperature detected by the third temperature sensor is Tb. Ta and Tb are inversely proportional.

[0016] Preferably, a second temperature sensor is provided on the mold for detecting the mold temperature. The temperature detected by the second temperature sensor is called Tm. The fluctuating temperature difference is obtained by the formula Tm-[59+0.5×(Ta-40)], which is called ΔT. If |ΔT|>1℃, the steam flow rate setting value of the heating furnace is corrected.

[0017] Preferably, it includes a slide table, a contact plate traction plate, and a signal transfer unit;

[0018] The slide is set parallel to one side of the trolley along the direction of linear movement of the trolley;

[0019] The contact plate is mounted on the slide and extends from the side of the slide toward the trolley;

[0020] The traction plate is horizontally fixed on the side wall of the trolley. When the traction plate moves with the trolley, it forms a moving path. The contact plate extends into the moving path of the traction plate. When the trolley moves, the traction plate pushes the slide table to move synchronously through the contact plate.

[0021] The signal conversion unit is divided into two parts and is respectively set on the trolley and the slide. The signal conversion unit is electrically connected to the first temperature sensor. Before the contact plate contacts the traction plate, the signal conversion unit is in an open circuit state. After the contact plate contacts the traction plate, the signal conversion unit is in a connected state.

[0022] Preferably, the synchronous detection device further includes a first linear driver and a horizontal pushing mechanism;

[0023] The first linear actuator is mounted on the slide with its output end facing the trolley, and the output end of the first linear actuator is fixedly connected to the contact plate.

[0024] The horizontal pushing mechanism is located at one end of the slide table along the direction of movement of the slide table. It has an origin position and a stop position on the movement path of the slide table. The slide table moves from the origin position to the stop position with the trolley. The horizontal pushing mechanism is used to push the slide table from the stop position to the origin position.

[0025] Preferably, the signal switching unit includes a first remote sensor, a second remote sensor, and a second linear driver;

[0026] The first remote sensor is mounted on the side wall of the trolley;

[0027] The second remote sensor is installed on the side wall of the slide table. When the trolley moves synchronously with the slide table, the first remote sensor and the second remote sensor are connected.

[0028] The second linear actuator is positioned on one side of the second remote sensor and is used to push the second remote sensor toward the direction of the first remote sensor.

[0029] Preferably, the signal switching unit further includes positioning protrusions and positioning recesses;

[0030] The positioning protrusion is located on one side of the first remote sensor;

[0031] The positioning recess is located on one side of the second remote sensor and is inserted into the positioning recess.

[0032] Preferably, there is an extension position on the moving path of the slide table, with the extension point located between the origin position and the stop position. A first proximity switch, a second proximity switch, and a third proximity switch are respectively provided on one side of the slide table corresponding to the origin position, the extension position, and the stop position.

[0033] Preferably, an overtake position is provided on the side of the stop position away from the origin position, and a fourth proximity switch is provided on the overtake position. The fourth proximity switch is used to detect the movement state of the slide table.

[0034] The advantages of this utility model compared to the prior art are:

[0035] 1. Improved dynamic temperature control accuracy: The heating furnace setpoint is adjusted in real time according to the mold temperature and external air conditions, reducing the temperature control deviation from ±3℃ to ±0.8℃;

[0036] 2. Reduced abnormal response time: The time for material injection interruption and alarm triggering has been reduced from 30 seconds to 0.1 seconds, and the defective product rate has decreased to below 0.5%;

[0037] 3. Enhanced environmental adaptability: When the outside temperature fluctuates within the range of -5℃ to 40℃, the mold temperature stability is maintained at ±1℃, improving the consistency of production throughout the four seasons.

[0038] 4. Reduced energy consumption: By dynamically adjusting the steam flow rate of the heating furnace through real-time temperature feedback, the steam consumption of the heating furnace is reduced by 12%, saving approximately 400,000 yuan in energy costs annually. Attached Figure Description

[0039] Figure 1 This is a system configuration diagram of the temperature synchronization detection device of this utility model.

[0040] Figure 2 This is a schematic diagram of the temperature synchronization detection device of this utility model.

[0041] Figure 3 This is a layout diagram of the second temperature sensor in the temperature synchronization detection device of this utility model.

[0042] Figure 4 This is a schematic diagram of the operation process of the temperature synchronization detection device of this utility model.

[0043] The following are the labels in the diagram: 1. Trolley; 2. Mold; 3. Second temperature sensor; 4. Slide table; 41. Contact plate; 42. Guide rail; 43. First linear actuator; 431. First magnetic switch; 432. Second magnetic switch; 44. Horizontal pushing mechanism; 45. First proximity switch; 46. Second proximity switch; 47. Third proximity switch; 48. Fourth proximity switch; 5. Traction plate; 6. First remote sensor; 61. Positioning protrusion; 7. Second remote sensor; 71. Positioning recess; 8. Second linear actuator; 81. Third magnetic switch. Detailed Implementation

[0044] To further understand the features, technical means, and specific objectives and functions achieved by this utility model, the following detailed description of this utility model is provided in conjunction with the accompanying drawings and specific embodiments.

[0045] Reference Figures 1-4 Temperature synchronous detection device is used to detect the temperature of mold 2 on trolley 1. A heating furnace that uses steam to heat mold 2 is set on one side of mold 2.

[0046] The synchronous detection device includes a first temperature sensor, which is set on one side of the heating furnace and used to detect the external temperature. The detected value is Ta. A third temperature sensor is set inside the heating furnace to detect the temperature inside the heating furnace. The temperature detected by the third temperature sensor is Tb. Ta and Tb are inversely proportional.

[0047] Trolley 1 consists of 50 trolleys arranged in a circular loop, driven by a chain. Since polyurethane products require a constant temperature above 59°C during production to ensure rigidity, the heating furnace must also maintain mold 2 at a temperature above 59°C when heating it with steam before material can be injected. However, after the heating furnace heats the air and supplies it to mold 2, heat dissipation occurs during the supply process, resulting in the actual temperature reaching mold 2 being lower than 59℃. Moreover, there are significant temperature differences between different months throughout the year, with the temperature difference between the coldest and hottest temperatures in many regions exceeding 40 degrees Celsius. Therefore, changes in the external temperature have a significant impact on the heating temperature at mold 2. To overcome this situation, a first temperature sensor is installed to detect the external temperature in real time and obtain a value Ta. By making Ta inversely proportional to Tb, the heating furnace uses a wind-circulating steam heat exchanger. When the value of Ta decreases, the heating furnace increases the steam flow, causing Tb to gradually increase. Conversely, when the value of Ta increases, the heating furnace slows down the steam flow, causing Tb to gradually decrease, thereby ensuring that the temperature at mold 2 is always above 59℃.

[0048] Reference Figures 1-4 A second temperature sensor 3 is installed on the mold 2 to detect the temperature of the mold 2. The temperature detected by the second temperature sensor 3 is called Tm. The fluctuating temperature difference is obtained by the formula Tm-[59+0.5×Ta-40]. The fluctuating temperature difference is called ΔT. If |ΔT|>1℃, the steam flow rate setting value of the heating furnace is corrected.

[0049] By installing a second temperature sensor 3 at mold 2, the temperature at mold 2 can be directly detected. Data from the first and second temperature sensors 3 is synchronously fed back, ensuring that the heating furnace can more accurately adjust the heating temperature, further guaranteeing that the temperature at mold 2 remains above 59 degrees Celsius. Furthermore, when the external temperature changes, temperature fluctuations occur during the heating furnace's temperature adjustment process. If only ensuring the mold 2 temperature is above 59 degrees Celsius is considered without considering these fluctuations, the defect rate will increase due to temperature fluctuations. Therefore, the fluctuating temperature difference ΔT is calculated using the formula Tm - [59 + 0.5 × Ta - 40], ensuring that the fluctuation difference |ΔT| < 1℃. If |ΔT| > 1℃, the steam flow rate setting of the heating furnace is corrected. This ensures that when the external air temperature fluctuates within the range of -5℃ to 40℃, the temperature stability of mold 2 remains within ±1℃, improving the consistency of production throughout the four seasons.

[0050] It is worth noting that the second temperature sensor 3 needs to perform five consecutive samples each time it detects, and then remove the highest and lowest values ​​from the five samples to calculate the average temperature. The temperature detected by the second temperature sensor 3, referred to as Tm, is the calculated average temperature, ensuring the accuracy of the second temperature sensor 3 in each detection of the mold 2. The range of Tm also needs to be manually set; this set temperature range is called the upper and lower limit management range. When the temperature Tm of the mold 2 exceeds the upper and lower limit management range, material injection into the mold 2 is stopped, saving material, and triggering an audible and visual alarm device, which includes a buzzer and a warning light.

[0051] In addition, when the temperature of the heating furnace is corrected, it is mainly corrected by the temperature controller built into the heating furnace. The temperature controller has PID calculation capability and dynamically corrects the heating furnace set value through PID self-tuning to compensate for the influence of ambient temperature fluctuations. The PID setting parameter setting range is: Kp=2.5, Ti=80s, Td=20s. The specific parameters can be set according to the actual situation.

[0052] By adjusting the heating furnace setting in real time according to the temperature of mold 2 and the external air conditions, the temperature control deviation at mold 2 is reduced from ±3℃ to ±0.8℃. At the same time, by dynamically adjusting the steam flow of the heating furnace through real-time temperature feedback, the steam consumption of the heating furnace is reduced by 12%.

[0053] Reference Figures 1-4 It includes a slide table 4, a contact plate 41, a traction plate 5, and a signal transfer unit;

[0054] The slide table 4 is arranged parallel to one side of the trolley 1 along the straight-line movement direction of the trolley 1;

[0055] The contact plate 41 is mounted on the slide table 4 and extends from the side of the slide table 4 toward the trolley 1;

[0056] The traction plate 5 is horizontally fixed on the side wall of the trolley 1. When the traction plate 5 moves with the trolley 1, it forms a moving path. The contact plate 41 extends into the moving path of the traction plate 5. When the trolley 1 moves, the traction plate 5 pushes the slide table 4 to move synchronously through the contact plate 41.

[0057] The signal transfer unit is divided into two parts and is respectively set on the trolley 1 and the slide table 4. The signal transfer unit is electrically connected to the first temperature sensor. Before the contact plate 41 contacts the traction plate 5, the signal transfer unit is in an open circuit state. After the contact plate 41 contacts the traction plate 5, the signal transfer unit is in a connected state.

[0058] A guide rail 42 is provided below the slide table 4 to guide the slide table 4. Although the trolleys 1 are arranged in a ring and circulate, the trolleys 1 still have a path of movement in a straight line during the movement. The slide table 4 is arranged parallel to one side of the path. When the trolley 1 moves to one side of the slide table 4, the trolley 1 drives the traction plate 5 to move towards the contact plate 41 on the slide table 4. Finally, the traction plate 5 contacts the contact plate 41 and pushes the contact plate 41. Then the slide table 4 and the trolley 1 move synchronously. The signal conversion unit switches from the open circuit state to the connected state. The second temperature sensor 3 transmits the signal through the signal conversion unit. The signal conversion unit is a wired connection. Through the conversion of the signal conversion unit, the wires of the second temperature sensor 3 are not tangled when it moves synchronously with the trolley 1. If a wireless method is used, there will be a delay in signal transmission. By setting the signal conversion unit, the fast signal transmission is ensured and the wear of the wire harness connected to the second temperature sensor 3 is avoided.

[0059] It is worth noting that multiple second temperature sensors 3 can be set according to the corresponding ports of the signal conversion unit. Multiple second temperature sensors 3 can correspond one-to-one with multiple molds 2 and synchronously detect the temperature of the molds 2. In this application, two second temperature sensors 3 are provided.

[0060] Reference Figures 1-4 The synchronous detection device also includes a first linear driver 43 and a horizontal pushing mechanism 44;

[0061] The first linear driver 43 is mounted on the slide table 4 with its output end facing the trolley 1. The output end of the first linear driver 43 is fixedly connected to the contact plate 41.

[0062] The horizontal pushing mechanism 44 is set at one end of the slide table 4 along the moving direction of the slide table 4. The slide table 4 has an origin position and a stop position on the moving path of the slide table 4. The slide table 4 moves from the origin position to the stop position with the trolley 1. The horizontal pushing mechanism 44 is used to push the slide table 4 from the stop position to the origin position.

[0063] The first linear actuator 43 is used to drive the contact plate 41 to move closer to or away from the trolley 1. When the first linear actuator 43 drives the contact plate 41 to move closer to the trolley 1, the contact plate 41 extends onto the moving path of the traction plate 5. At this time, the slide table 4 is at the origin. After the contact plate 41 contacts the traction plate 5, the trolley 1 drives the slide table 4 to move synchronously. The slide table 4 moves from the origin to the stop position. When the slide table 4 reaches the stop position, the first linear actuator 43 drives the contact plate 41 to retract. At this time, the contact plate 41 is removed from the moving path of the traction plate 5, and the slide table 4 no longer moves synchronously with the trolley 1. At this time, the slide table 4 has not yet reached the end of the guide rail 42. Then, the horizontal pushing mechanism 44 pushes the slide table 4 from the stop position back to the origin position. The horizontal pushing mechanism 44 can be selected from screw and nut type, synchronous belt drive type, gear and rack type, electric push rod, hydraulic cylinder and pneumatic cylinder, etc.

[0064] A first magnetic switch 431 and a second magnetic switch 432 are provided on one side of the first linear driver 43. The first magnetic switch 431 and the second magnetic switch 432 are arranged along the extension direction of the first linear driver 43 and respectively detect the extended or retracted state of the output end of the first linear driver 43 to confirm the extension and retraction state of the contact plate 41.

[0065] Reference Figures 1-4 The signal switching unit includes a first remote sensor 6, a second remote sensor 7, and a second linear driver 8.

[0066] The first remote sensor 6 is mounted on the side wall of the trolley 1;

[0067] The second remote sensor 7 is installed on the side wall of the slide table 4. When the trolley 1 moves synchronously with the slide table 4, the first remote sensor 6 and the second remote sensor 7 are connected.

[0068] The second linear actuator 8 is disposed on one side of the second remote sensor 7 and is used to push the second remote sensor 7 to move toward the first remote sensor 6.

[0069] When the trolley 1 and the slide table 4 move synchronously, the first remote sensor 6 and the second remote sensor 7 are aligned. The second linear driver 8 pushes the second remote sensor 7 toward the first remote sensor 6, and connects the first remote sensor 6 and the second remote sensor 7, thereby ensuring that the signal transfer unit can transmit signals to the second temperature sensor 3 in real time when the trolley 1 and the slide table 4 move synchronously.

[0070] The first remote sensor 6 and the second remote sensor 7 adopt the B&Plus RS02 series remote sensors. The first remote sensor 6 adopts RS02T-030-K300 and the second remote sensor 7 adopts RS02E-030E-PU10. With the SMPW-CC-K series quick connector, the change speed of mold 2 is improved when changing different molds 2.

[0071] Reference Figures 1-4 The signal conversion unit also includes a positioning protrusion 61 and a positioning recess 71;

[0072] The positioning protrusion 61 is located on one side of the first remote sensor 6;

[0073] The positioning recess 71 is located on one side of the second remote sensor 7 and is inserted and engaged with the positioning recess 71.

[0074] The positioning protrusion 61 and positioning recess 71 are used to assist in positioning the first remote sensor 6 and the second remote sensor 7 before connection, so as to ensure that the first remote sensor 6 and the second remote sensor 7 can be connected smoothly.

[0075] Reference Figures 1-4 There is also an extension position on the moving path of the slide table 4. The extension point is located between the origin position and the stop position. A first proximity switch 45, a second proximity switch 46 and a third proximity switch 47 are respectively set on one side of the slide table 4 corresponding to the origin position, the extension position and the stop position.

[0076] The first proximity switch 45 and the third proximity switch 47 detect the position of the moving slide table 4. The second proximity switch 46 is used to detect the moving position of the trolley 1. The first proximity switch 45 is used to confirm whether the slide table 4 has returned to the original position. The third proximity switch 47 is used to confirm whether the slide table 4 has moved to the stop position. When the trolley 1 moves to the second proximity switch 46, the contact plate 41 extends out under the action of the first linear driver 43 and extends into the moving path of the traction plate 5.

[0077] Reference Figures 1-4 An overtake position is also provided on the side of the stop position away from the origin position. A fourth proximity switch 48 is provided on the overtake position. The fourth proximity switch 48 is used to detect the movement status of the slide table 4.

[0078] When the slide table 4 moves to the stop position with the trolley 1, the contact plate 41 does not retract, and the slide table 4 will move synchronously with the trolley 1. In order to prevent the slide table 4 from being pulled off the guide rail 42 by the trolley 1, a fourth proximity switch 48 is set. When the slide table 4 reaches the fourth proximity switch 48, an abnormality is determined and the machine stops and alarms.

[0079] The above embodiments only illustrate one or more implementations of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the appended claims.

Claims

1. Temperature synchronous detection device, used to detect the temperature of mold (2) on trolley (1), and a heating furnace that uses steam to heat the mold (2) is provided on one side of the mold (2); Its features are, The synchronous detection device includes a first temperature sensor, which is set on one side of the heating furnace and used to detect the external temperature. The detected value is Ta. A third temperature sensor is set inside the heating furnace to detect the temperature inside the heating furnace. The temperature detected by the third temperature sensor is Tb. Ta and Tb are inversely proportional.

2. The temperature synchronization detection device according to claim 1, characterized in that, A second temperature sensor (3) is provided on the mold (2) for detecting the temperature of the mold (2). The temperature detected by the second temperature sensor (3) is called Tm. The fluctuating temperature difference is obtained by the formula Tm-[59+0.5×(Ta-40)]. The fluctuating temperature difference is called ΔT. If |ΔT|>1℃, the steam flow rate setting value of the heating furnace is corrected.

3. The temperature synchronization detection device according to claim 1, characterized in that, It includes a slide (4), a contact plate (41), a traction plate (5), and a signal transfer unit; The slide (4) is set parallel to one side of the trolley (1) along the straight-line movement direction of the trolley (1); The contact plate (41) is set on the slide (4) and extends from the side of the slide (4) toward the trolley (1); The traction plate (5) is horizontally fixed on the side wall of the trolley (1). When the traction plate (5) moves with the trolley (1), it forms a moving path. The contact plate (41) extends into the moving path of the traction plate (5). When the trolley (1) moves, the traction plate (5) pushes the slide (4) to move synchronously through the contact plate (41). The signal transfer unit is divided into two parts and is respectively set on the trolley (1) and the slide (4). The signal transfer unit is electrically connected to the first temperature sensor. Before the contact plate (41) contacts the traction plate (5), the signal transfer unit is in an open circuit state. After the contact plate (41) contacts the traction plate (5), the signal transfer unit is in a connected state.

4. The temperature synchronization detection device according to claim 3, characterized in that, The synchronous detection device also includes a first linear drive (43) and a horizontal pushing mechanism (44); The first linear driver (43) is mounted on the slide (4) with its output end facing the trolley (1). The output end of the first linear driver (43) is fixedly connected to the contact plate (41). The horizontal pushing mechanism (44) is set at one end of the slide (4) along the moving direction of the slide (4). The slide (4) has an origin position and a stop position on the moving path of the slide (4). The slide (4) moves from the origin position to the stop position with the trolley (1). The horizontal pushing mechanism (44) is used to push the slide (4) from the stop position to the origin position.

5. The temperature synchronization detection device according to claim 3, characterized in that, The signal switching unit includes a first remote sensor (6), a second remote sensor (7), and a second linear driver (8); The first remote sensor (6) is mounted on the side wall of the trolley (1); The second remote sensor (7) is set on the side wall of the slide (4). When the trolley (1) moves synchronously with the slide (4), the first remote sensor (6) and the second remote sensor (7) are connected. The second linear actuator (8) is located on one side of the second remote sensor (7) and is used to push the second remote sensor (7) to move in the direction of the first remote sensor (6).

6. The temperature synchronization detection device according to claim 5, characterized in that, The signal switching unit also includes a positioning protrusion (61) and a positioning recess (71); The positioning protrusion (61) is located on one side of the first remote sensor (6); The positioning recess (71) is located on one side of the second remote sensor (7) and is inserted into the positioning recess (71).

7. The temperature synchronization detection device according to claim 3, characterized in that, There is also an extension position on the moving path of the slide table (4). The extension point is located between the origin position and the stop position. A first proximity switch (45), a second proximity switch (46) and a third proximity switch (47) are respectively provided on one side of the slide table (4) corresponding to the origin position, the extension position and the stop position.

8. The temperature synchronization detection device according to claim 7, characterized in that, An overtake position is also provided on the side of the stop position away from the origin position. A fourth proximity switch (48) is provided on the overtake position. The fourth proximity switch (48) is used to detect the movement state of the slide (4).

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