Foam Production Hardness Prediction for Real-Time Parameter Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current polyurethane foam production methods cannot measure foam hardness in real time during the manufacturing process, leading to the production of foams with unqualified hardness, as hardness measurement is typically done after 24 hours of curing in a laboratory, preventing effective quality control.
Innovation Solution
A method and system that measures cut surface hardness information on a conveyor belt, uses a conversion relationship formed from historical data to predict the cured hardness, and adjusts production parameters in real time using a neural network or machine learning algorithm to ensure the foam meets desired hardness specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If foam hardness is measured after 24 hours of curing in a laboratory, then measurement accuracy is improved, but production efficiency deteriorates and real-time quality control becomes impossible
Solution Approach 1:
The system performs preliminary hardness measurement on the foam cut surface immediately after cutting, before the foam completes its curing process. This preliminary measurement allows prediction of the final cured hardness, enabling real-time quality control without waiting 24 hours for complete curing, thus resolving the contradiction between measurement accuracy and production efficiency
Solution Approach 2:
The patent replaces the traditional mechanical laboratory hardness testing method with an automated optical or electrical measurement system that can operate on the production line. This substitution enables continuous real-time measurement and prediction, maintaining accuracy while dramatically improving productivity by eliminating the 24-hour waiting period
2Productivity
If foam hardness is measured in real time on the production line, then productivity is improved, but measurement precision deteriorates due to incomplete curing
Solution Approach 1:
The system introduces a conversion relationship model as an intermediary between the preliminary cut surface hardness measurement and the predicted cured hardness. This model, trained on historical data, translates the early measurement into an accurate prediction of final hardness, maintaining measurement precision while enabling real-time measurement on the production line
Solution Approach 2:
The patent creates a virtual copy of the curing process through machine learning models that simulate how the foam hardness will evolve over time. By measuring the cut surface and using the model to predict the cured state, the system achieves accurate hardness assessment without physically waiting for complete curing, thus maintaining precision while improving productivity
3Manufacturing precision
If production parameters are adjusted frequently to control foam hardness, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system implements a closed-loop feedback mechanism where real-time cut surface hardness measurements are continuously fed back to the control system. The conversion relationship model predicts the cured hardness, and the system automatically adjusts production parameters accordingly. This automated feedback loop improves manufacturing precision while managing device complexity through systematic control architecture
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for adjusting parameters for foam production, determining hardness conversion relationship, a device for foam production and a medium. The method for adjusting parameters for production comprises the following steps: measuring the cut surface hardness information of the foam on the conveyor of the foam production line; determining the predicted hardness information of the foam after curing based on a conversion relationship according to the cut surface hardness information, the conversion relationship being formed according to the historical data of the cut surface hardness information and the cured hardness information of the foam; and adjusting the production parameters of the foam according to the predicted hardness information. By means of the method, the hardness of the foam on the production line after curing may be predicted in real time or quasi real time, and the hardness may be adjusted adaptively.