Electrically controlled air supply device for polyurethane foaming line

Abstract

The utility model relates to polyurethane foaming technical field, concretely is related to polyurethane foaming line's electric control gas supply device, including execution module, control module and feedback module, execution module contains set type electromagnetic valve and air cylinder, and set type electromagnetic valve controls the valve core displacement of air cylinder through electric signal, control module contains PLC controller, is used for sending control signal to execution module, feedback module contains position sensor and pressure sensor, and position sensor is used for detecting the valve core position of air cylinder, and pressure sensor is used for detecting gas supply pressure, and feedback module will detected signal feedback to PLC controller, forms closed loop control. Feedback module will the signal that position sensor and pressure sensor gathered real -time transmission to PLC controller, and PLC controller will these actual detection value with preset target value carry out comparison operation, and according to the deviation adjustment control signal that exports to execution module, to form " set value - detection value - deviation adjustment " closed loop control.

Description

Technical Field

[0001] This utility model relates to the field of polyurethane foaming technology, specifically to an electro-controlled gas supply device for a polyurethane foaming line. Background Technology

[0002] In the production of sponge, the air supply device is a key piece of equipment to ensure the smooth progress of processes such as foaming and curing. Its performance directly affects the quality of the sponge product and the efficiency of the production line. Currently, existing polyurethane foaming lines generally use mechanical control valves to control the opening and closing of the air supply pipeline, regulate the flow rate, and trigger the actions of various transmission mechanisms. Its core working principle relies on the movement of mechanical structures such as mechanical springs, cams, or levers to trigger the valve action, thereby completing the air supply process.

[0003] However, this mechanically based control method has many insurmountable problems in practical applications: First, high-frequency operation leads to a high failure rate. The air supply trolley needs to complete an air supply cycle every 10 seconds, including valve opening, flow regulation, and closing, with more than 8,000 operations per day. Under this high-frequency operation, the wear rate of the valve core and seals of the mechanically controlled valve is greatly accelerated, with an average lifespan of only 1-2 months. Frequent component wear not only results in annual replacement costs as high as 50,000 yuan, but more seriously, once the mechanically controlled valve fails and stops, it will directly lead to a supply disruption of the sponge production line, with losses exceeding 20,000 yuan for a single failure.

[0004] Secondly, the control precision is insufficient. The flow regulation of the mechanically controlled valve relies on mechanical limits, which cannot achieve stable flow control. The actual air supply error reaches ±5%, while the process requires the error to be controlled within ±2%. The instability of the flow leads to fluctuations in the foam density of the sponge, with a defect rate of approximately 3%, affecting product quality and production efficiency.

[0005] Secondly, the response lag is a significant issue. Unavoidable gaps exist in the mechanical transmission process, causing a 0.2-0.3 second delay in valve action. This makes it impossible to match the production line's rhythm, easily leading to gas supply timing deviations, and consequently affecting the continuity and stability of sponge production.

[0006] Finally, maintenance is difficult. The internal structure of the mechanically controlled valve is complex. When a malfunction occurs, troubleshooting requires disassembling the valve body, and the system lacks real-time fault diagnosis capabilities. After an abnormal shutdown, manual troubleshooting is essential, resulting in an average recovery time of up to 40 minutes per incident, severely impacting production continuity. Although traditional improvement methods, such as replacing wear-resistant materials and increasing lubrication, can extend the lifespan of the mechanically controlled valve to some extent, this extension is at most 10%-15%, failing to fundamentally resolve the precision and reliability issues arising from the inherent wear characteristics of the mechanical structure and the demands of high-frequency dynamic response. Therefore, the electrification of the gas supply device in the polyurethane foaming line to overcome the shortcomings of existing mechanical control methods has become an urgent need to improve the quality and efficiency of foam production. Utility Model Content

[0007] To address the aforementioned issues, an electro-controlled gas supply device for polyurethane foaming lines is provided. Through the coordinated operation of the execution module, control module, and feedback module, a closed-loop system controlled by electrical signals is constructed, solving the problems of easy failure, insufficient control accuracy, lag response, and difficult maintenance associated with mechanical control valves.

[0008] To address the problems of existing technologies, this utility model provides an electrically controlled air supply device for a polyurethane foaming line, comprising an execution module, a control module, and a feedback module. The execution module includes a manifold solenoid valve and a cylinder, wherein the manifold solenoid valve controls the displacement of the cylinder's valve core via an electrical signal. The control module includes a PLC controller for sending control signals to the execution module. The feedback module includes a position sensor and a pressure sensor; the position sensor detects the position of the cylinder's valve core, and the pressure sensor detects the air supply pressure. The feedback module feeds back the detected signals to the PLC controller, forming a closed-loop control.

[0009] Preferably, the execution module further includes an air supply nozzle, and the piston rod of the cylinder is rigidly connected to the air supply nozzle to drive the air supply nozzle to perform linear displacement.

[0010] Preferably, the position sensor includes multiple proximity switches, which are used to detect the device origin, the forward position of the air supply nozzle, the air supply stop position, and the overtravel protection position, respectively.

[0011] Preferably, the control module further includes a touch screen that can display the air supply pressure, trolley position and alarm codes, and supports parameter settings and switching between automatic and manual operation modes.

[0012] Preferably, the PLC controller is connected to the MES system via an industrial bus, enabling remote monitoring and fault early warning functions.

[0013] Preferably, the electro-controlled gas supply device of the polyurethane foaming line is also equipped with a safety interlock mechanism, which includes over-travel protection, abnormal air pressure alarm, safety relay, and trolley position verification function.

[0014] Preferably, the PLC controller is equipped with adaptive control logic, which can automatically adjust the air supply pressure curve according to the process segment of the sponge production line, thereby matching the flow demand within a 10-second cycle.

[0015] Preferably, the proximity switch is mounted using a waist-shaped hole bracket, allowing for ±5mm of fine-tuning in position.

[0016] The advantages of this utility model compared to the prior art are:

[0017] The feedback module transmits the signals collected by the position and pressure sensors to the PLC controller in real time. The PLC controller compares these actual detection values ​​with the preset target values ​​and adjusts the output control signal to the execution module according to the deviation, thus forming a closed-loop control of "set value - detection value - deviation adjustment" to ensure that the air supply pressure and valve core position always meet the process requirements. Attached Figure Description

[0018] Figure 1 This is a front view of the electro-controlled gas supply device for the polyurethane foaming line of this utility model.

[0019] Figure 2 This is a top view of the electro-controlled gas supply device for the polyurethane foaming line of this utility model.

[0020] Figure 3 This is a flowchart of the electro-controlled gas supply device for the polyurethane foaming line of this utility model.

[0021] The components in the diagram are labeled as follows: Execution module 1, cylinder 10, air supply nozzle 11, control module 2, feedback module 3, position sensor 30, and proximity switch 300. Detailed Implementation

[0022] 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.

[0023] like Figure 1-3As shown, this utility model provides an electronically controlled air supply device for a polyurethane foaming line, including an execution module 1, a control module 2, and a feedback module 3. The execution module 1 includes a manifold solenoid valve and a cylinder 10. The manifold solenoid valve controls the valve core displacement of the cylinder 10 through an electrical signal. The control module 2 includes a PLC controller for sending control signals to the execution module 1. The feedback module 3 includes a position sensor 30 and a pressure sensor. The position sensor 30 is used to detect the valve core position of the cylinder 10, and the pressure sensor is used to detect the air supply pressure. The feedback module 3 feeds back the detected signals to the PLC controller to form a closed-loop control.

[0024] As a direct response element to electrical signals, the manifold solenoid valve receives electrical signals (such as voltage or current signals) from the control module 2. It then changes the valve core position by switching its internal solenoid coil on and off, thereby controlling the intake and exhaust of the cylinder 10. The manifold solenoid valve is connected to the cylinder 10 via a pipeline. When the solenoid valve receives a control signal, its internal valve port switches, allowing compressed air to enter the rodless or rod chamber of the cylinder 10. This pushes the piston of the cylinder 10 and the connected valve core to produce linear displacement, thus opening, closing, or regulating the flow rate of the air supply pipeline. This direct electrical signal control method eliminates the backlash in traditional mechanical transmissions, ensuring precise operation.

[0025] The PLC controller sends electrical signals to the manifold solenoid valve of the execution module 1 through its output interface. The frequency, duration, and other parameters of these signals determine the operating state of the solenoid valve, thereby controlling the displacement and speed of the valve core of the cylinder 10, and achieving active control of the air supply process. For example, in different process sections (foaming, curing) of the sponge production line, the PLC controller will send different control signals to match the corresponding air supply requirements.

[0026] Position sensor 30 is used to detect the valve core position of cylinder 10 in real time. Its installation position corresponds to the movement trajectory of cylinder 10, and it can accurately capture the displacement and position of the valve core (such as fully open, fully closed, or a certain intermediate adjustment position), and convert the position signal (usually a switch signal or analog signal) into an electrical signal and transmit it to the PLC controller. Pressure sensor is installed at key nodes of the air supply pipeline (such as the inlet end of air nozzle 11) to continuously detect the real-time value of the air supply pressure, and converts the pressure signal into an electrical signal that can be recognized by the PLC controller for feedback. Feedback module 3 transmits the signals collected by position sensor 30 and pressure sensor to PLC controller in real time. PLC controller compares these actual detection values ​​with preset target values ​​(such as target air supply pressure, target valve core position), and adjusts the output control signal to execution module 1 according to the deviation, thereby forming a closed-loop control of "set value - detection value - deviation adjustment" to ensure that the air supply pressure and valve core position always meet the process requirements.

[0027] When the system is working, the PLC controller of control module 2 first sets the air supply parameters (such as target pressure and valve core position) according to production requirements, and sends an initial control signal to the manifold solenoid valve of execution module 1 to drive the valve core of cylinder 10 to move. At the same time, the position sensor 30 and pressure sensor of feedback module 3 detect the actual position of the valve core and the actual air supply pressure, respectively, and feed the signals back to the PLC controller. The PLC controller compares the actual value with the set value. If there is a deviation, it immediately adjusts the output signal until the actual value matches the set value. This dynamic adjustment process continues, ensuring the stability and accuracy of the air supply.

[0028] The execution module 1 also includes an air supply nozzle 11, with the piston rod of the cylinder rigidly connected to the air supply nozzle 11 to drive it to perform linear displacement. The position sensor 30 includes multiple proximity switches 300, used to detect the device origin, the forward position of the air supply nozzle 11, the air supply stop position, and the overtravel protection position, respectively. Figure 3 As shown, the overtravel protection position can prevent the displacement of components from exceeding the normal range due to unexpected situations such as mechanical jamming or signal interference. The proximity switch 300 set in the overtravel protection position can detect whether the component exceeds the safe displacement threshold in real time. Once triggered, it immediately sends a signal to the PLC controller to quickly execute emergency operations (such as emergency retraction of the air supply nozzle 11 / contact plate, or production line shutdown) to avoid equipment damage or production accidents.

[0029] The control module 2 also includes a touch screen that can display the air supply pressure, trolley position and alarm codes, and supports parameter settings and switching between automatic and manual operation modes.

[0030] The PLC controller is connected to the MES system via an industrial bus, enabling remote monitoring and fault early warning functions.

[0031] The electro-controlled air supply system of the polyurethane foaming line is also equipped with a safety interlock mechanism, which includes over-travel protection, abnormal air pressure alarm, safety relay, and trolley position verification function. The abnormal air pressure alarm function (triggered when the air supply pressure is below 0.4MPa) monitors the air source status in real time. When the pressure deviates from the process requirements, the PLC controller cuts off the automatic operation signal and sounds an alarm, preventing air flow fluctuations caused by insufficient air pressure. This ensures air pressure stability during foaming and curing processes, reducing product quality defects caused by air source problems. The trolley position verification function (e.g., confirming the device origin via proximity SW① or identifying the trolley number via RFID) ensures that the air supply system only starts the air supply process when the trolley reaches the preset air supply position. This avoids air supply timing errors caused by trolley position deviations (such as premature or delayed air supply), ensuring precise matching of the air supply cycle with the production line cycle time (10 seconds / cycle), reducing production line interruptions or product defects caused by synchronization issues.

[0032] The PLC controller is equipped with adaptive control logic, which can automatically adjust the air supply pressure curve according to the process stage of the sponge production line to match the flow demand within a 10-second cycle. The system can automatically identify the current process stage of the sponge production line (such as the foaming stage or the curing stage). This identification is based on the process stage signal transmitted from the production line or the initial pressure characteristics detected by the pressure sensor. For the air consumption characteristics of different process stages, the PLC controller has pre-stored corresponding air supply pressure curve models. For example, in the foaming stage, because a stable air pressure needs to be established quickly to ensure uniform foam generation, the pressure curve will show the characteristic of "rapidly rising to the set value and then remaining stable"; while in the curing stage, the air pressure demand is relatively low and stable, and the curve is flatter. The 10-second cycle can be: 0-2 seconds rapid opening stage: The PLC controller sends a strong electrical signal to the integrated solenoid valve, driving the cylinder 10 to move quickly, so that the air supply nozzle 11 quickly reaches the working position and starts supplying air. At this time, the pressure sensor provides real-time feedback of the pressure value, and the controller quickly adjusts the opening of the solenoid valve according to the feedback to ensure that the pressure rises quickly to the initial value required by the process. 2-8 Second Stabilization Phase: Once the pressure reaches the set value, the system enters the stabilization phase. The PLC controller monitors the valve core position of cylinder 10 via position sensor 30, and, combined with real-time data from the pressure sensor, uses a closed-loop control algorithm to finely adjust the solenoid valve's movement, ensuring the air supply flow remains stable within the set range with an error controlled within ±2%, meeting the stable air source requirements for sponge production. 8-10 Second Buffer Closure Phase: Near the end of the cycle, the controller sends a signal to gradually close the solenoid valve, preventing a sudden pressure drop due to a sudden interruption in air supply and minimizing the impact on the sponge production process. Simultaneously, position sensor 30 detects the retraction position of the air supply nozzle 11, ensuring accurate reset and preparing for the next cycle.

[0033] The proximity switch 300 is mounted using a slotted bracket, allowing for ±5mm of fine-tuning in position.

[0034] like Figure 3 The diagram shows the workflow of the electro-controlled gas supply device for this polyurethane foaming line. The operation process is as follows:

[0035] 1. The gas supply device usually takes the position close to SW① as the origin. At this time, the gas supply device is in standby mode. When a gas supply command is received, the contact plate extends and the gas supply nozzle 11 is in the retracted state.

[0036] 2. The contact plate contacts the traction plate on the mold trolley, causing the air supply device to move forward synchronously with the mold trolley.

[0037] 3. When the gas supply device comes into contact with SW②, the gas supply nozzle 11 moves forward to start supplying gas, and the gas supply start signal is set by the timer of the PLC.

[0038] 4. When the gas supply device comes into contact with SW③, the gas supply nozzle 11 stops supplying gas, the gas supply nozzle 11 retracts, and the contact plate also retracts. If the gas supply assembly stops between SW② and SW③, the timer of the PLC controls the gas supply to stop.

[0039] 5. Once the magnetic switch SW① of cylinder 10 is confirmed and the air supply nozzle 11 returns, the contact plate will retract.

[0040] 6. Once the magnetic switch SW② of cylinder 10 is confirmed to return to the contact plate, the air supply assembly returns to its original position.

[0041] 7. Once the gas supply component comes into contact with the proximity SW① of the origin, the contact plate extends.

[0042] It should be noted that the PLC controller acquires the position signal of the mold trolley from the ASTMAC system through the ETHRENET network to achieve position tracking with the mold trolley. The air supply device is in standby mode by default at the origin position corresponding to SW①. The ASTMAC system continuously sends the real-time position signal of the mold trolley to the PLC controller.

[0043] 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. An electro-controlled gas supply device for a polyurethane foaming line, characterized in that, It includes an execution module (1), a control module (2), and a feedback module (3); the execution module (1) includes a manifold solenoid valve and a cylinder (10), the manifold solenoid valve controls the valve core displacement of the cylinder (10) through an electrical signal; the control module (2) includes a PLC controller, which is used to send control signals to the execution module (1); the feedback module (3) includes a position sensor (30) and a pressure sensor, the position sensor is used to detect the valve core position of the cylinder (10), the pressure sensor is used to detect the air supply pressure, and the feedback module (3) feeds back the detected signals to the PLC controller to form a closed-loop control.

2. The electrically controlled gas supply device for a polyurethane foaming line according to claim 1, characterized by The execution module (1) also includes an air supply nozzle (11), and the piston rod of the cylinder (10) is rigidly connected to the air supply nozzle (11) to drive the air supply nozzle (11) to perform linear displacement.

3. The electro-controlled gas supply device for the polyurethane foaming line according to claim 1, characterized in that, The position sensor (30) includes multiple proximity switches (300) for detecting the device origin, the forward position of the air supply nozzle (11), the air supply stop position, and the overtravel protection position, respectively.

4. The electrically controlled gas supply device for a polyurethane foaming line according to claim 1, wherein The control module (2) also includes a touch screen, which can display the air supply pressure, trolley position and alarm code, and supports parameter settings and switching between automatic and manual operation modes.

5. The electrically controlled gas supply device for a polyurethane foaming line according to claim 1, wherein The PLC controller is connected to the MES system via an industrial bus, enabling remote monitoring and fault early warning functions.

6. The electrically controlled gas supply device for a polyurethane foaming line according to claim 1, wherein The electro-controlled gas supply device of the polyurethane foaming line is also equipped with a safety interlock mechanism, which includes over-travel protection, abnormal gas pressure alarm, safety relay, and trolley position verification function.

7. The electrically controlled gas supply device for a polyurethane foaming line according to claim 1, wherein The PLC controller is equipped with adaptive control logic, which can automatically adjust the air supply pressure curve according to the process section of the sponge production line, thereby matching the flow demand within a 10-second cycle.

8. The electro-controlled gas supply device for the polyurethane foaming line according to claim 3, characterized in that, The proximity switch (300) is mounted using a waist-shaped hole bracket, allowing for ±5mm of positional fine-tuning.

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