CN118034213B - A production quality supervision system for crack-proof hollow boards - Google Patents
A production quality supervision system for crack-proof hollow boards Download PDFInfo
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32368—Quality control
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Abstract
The invention discloses a production quality supervision system of an anti-cracking hollow plate, which relates to the technical field of production supervision of the hollow plate, wherein a fusion model outputs quality amplitude values for the production process of the anti-cracking hollow plate, a set dividing module divides the anti-cracking hollow plate into a defect-free set, a defect set or a defect set according to the comparison result of the quality amplitude values and gradient threshold values, if the anti-cracking hollow plate is divided into the defect set, a defect judging module analyzes that the anti-cracking hollow plate has a latent defect, if the anti-cracking hollow plate is divided into the defect set, a secondary judging module analyzes environmental factors during the production of the anti-cracking hollow plate, and judges whether the anti-cracking hollow plate in the defect set has the latent defect according to the environmental factors. The monitoring system can monitor technological parameters in the generation process of the anti-cracking hollow plate and comprehensively analyze whether the anti-cracking hollow plate has a latent defect by combining environmental factors, so that corresponding management is carried out when the anti-cracking hollow plate is found to have the latent defect, and the service life of the anti-cracking hollow plate is effectively ensured.
Description
Technical Field
The invention relates to the technical field of hollow plate production supervision, in particular to an anti-cracking hollow plate production quality supervision system.
Background
An anti-crack hollow panel is a construction material for the construction field, which is designed to reduce or prevent cracks and damages in a construction structure, and is generally made of a lightweight material such as polystyrene (EPS) or polyurethane foam, etc., having good heat and sound insulation properties, and is widely used in construction structures such as walls, floors and roofs to improve stability and durability of a building, and a supervisory system is a system for detecting and managing after the anti-crack hollow panel is produced.
The prior art has the following defects:
The existing supervision system generally detects the quality of the anti-cracking hollow plate after the anti-cracking hollow plate is produced to judge whether the production quality of the anti-cracking hollow plate meets the standard, however, when the anti-cracking hollow plate is affected by various adverse factors in the actual production process, the anti-cracking hollow plate has a latent defect, the latent defect cannot be detected after the anti-cracking hollow plate is produced, and the service life of the anti-cracking hollow plate is shortened;
Based on the method, the production quality supervision system of the anti-cracking hollow plate can monitor whether the anti-cracking hollow plate possibly has latent defects in the generation process of the anti-cracking hollow plate, so that the service life of the anti-cracking hollow plate is prolonged.
Disclosure of Invention
The invention aims to provide an anti-cracking hollow plate production quality supervision system which aims to solve the defects in the background technology.
In order to achieve the aim, the invention provides the technical scheme that the anti-cracking hollow plate production quality supervision system comprises a monitoring module, a control module, a data acquisition module, a characteristic extraction module, an analysis module, a set dividing module, a defect judgment module, a secondary judgment module and a management module;
the monitoring module is used for monitoring each process in real time in the production process of the anti-cracking hollow plate;
The control module stops the process when the monitoring index of a certain process step is abnormal, and sends abnormal index information to an administrator;
the data acquisition module is used for acquiring a plurality of technological parameters related to the quality of the finished product of the anti-cracking hollow plate after the production of the anti-cracking hollow plate is completed;
The feature extraction module is used for preprocessing a plurality of process parameters and extracting features to obtain process feature data;
the analysis module is used for comprehensively analyzing a plurality of process characteristic data through the fusion model and outputting quality amplitude values for the production process of the anti-cracking hollow plate;
The set dividing module is used for dividing the anti-cracking hollow plate into a non-defect set, a defect set to be determined or a defect set according to the comparison result of the quality amplitude and the gradient threshold value;
The defect judging module is used for analyzing the hidden defect of the anti-cracking hollow plate if the anti-cracking hollow plate is scratched into the defect set, automatically controlling the production stop of the anti-cracking hollow plate and sending a warning signal to an administrator;
The secondary judging module is used for analyzing environmental factors when the anti-cracking hollow plates are produced if the anti-cracking hollow plates are marked into the defect set to be determined, judging whether the anti-cracking hollow plates in the defect set to be determined have latent defects or not according to the environmental factors, generating corresponding management strategies according to the judging results and sending the management strategies to an administrator;
And the management module is used for judging whether the production line is required to be managed after analyzing the aggregate division result of the anti-cracking hollow plates in the batch after the production line finishes producing the anti-cracking hollow plates in the batch, and sending the judgment result to an administrator.
In a preferred embodiment, the feature extraction module extracts feature acquisition process feature data, which includes mixture trajectory similarity, foam dose bias, and structural assignments.
In a preferred embodiment, the analysis module substitutes the similarity of the mixing track, the deviation of the foaming agent amount and the structural assignment into the fusion model for comprehensive analysis, and the output quality amplitude of the production process of the anti-cracking hollow plate is expressed as a function expression:
Wherein zl f is the mass amplitude, JGF is the structure assignment, GJX is the mixing track similarity, FPC is the foam agent amount deviation, alpha, beta and gamma are the structure assignment, the mixing track similarity and the ratio coefficient of the foam agent amount deviation respectively, and alpha, beta and gamma are all larger than 0.
In a preferred embodiment, the logic for obtaining the structural amplitude is:
In the hardening process of the anti-cracking hollow plate, obtaining hardening time and hardening temperature of the anti-cracking hollow plate in real time;
marking a time period when the hardening time exceeds a time threshold value as a time standard time period, and marking a time period when the real-time temperature is not within a preset temperature range as a temperature early warning time period after the real-time temperature of the anti-cracking hollow plate in the hardening process is obtained;
and carrying out integral operation on the time length standard period and the temperature early warning period to obtain a structural amplitude, wherein the function expression is as follows: q (t) is the intensity variation of the anti-cracking hollow plate, [ t x,ty ] is the time length standard period, [ t i,tj ] is the temperature early warning period.
In a preferred embodiment, the logic for obtaining the similarity of the mixed track is:
Acquiring coordinates of preset n sampling points on a real-time motion track of a mixing mechanism, wherein n is more than or equal to 2, n is a positive integer, calculating the similarity between the actual coordinates of each sampling point and corresponding standard coordinates, adding the coordinate similarity of the n sampling points to obtain the similarity of the mixing track, and the function expression is as follows:
Wherein i=1, 2,3,..n, n is the number of sampling points on the real-time motion track of the mixing mechanism, gj i represents the coordinate similarity of the i-th sampling point;
The coordinate similarity calculation expression of the sampling point is as follows: Where (x 1,y1) is the actual coordinates of the sampling point and (x 2,y2) is the standard coordinates of the sampling point.
In a preferred embodiment, after the set dividing module obtains the quality assignment, comparing the obtained quality assignment with a preset gradient threshold;
the gradient threshold comprises a first defect threshold and a second defect threshold, the first defect threshold is used for judging whether the hidden defect exists in the anti-cracking hollow plate, the second defect threshold is used for judging the severity of the hidden defect of the anti-cracking hollow plate, and the first defect threshold is smaller than the second defect threshold;
if the mass amplitude is smaller than or equal to the first defect threshold value, judging that the anti-cracking hollow plate does not have a latent defect, and scribing the anti-cracking hollow plate into a defect-free set;
If the mass amplitude is larger than the first defect threshold, judging that the crack-proof hollow plate has a latent defect;
If the mass amplitude is larger than the first defect threshold value and the mass amplitude is smaller than or equal to the second defect threshold value, judging that the hidden defect of the anti-cracking hollow plate is small, and scribing the anti-cracking hollow plate into a defect set;
If the mass amplitude is larger than the second defect threshold, judging that the hidden defect of the anti-cracking hollow plate is large, and scribing the anti-cracking hollow plate into the defect set.
In a preferred embodiment, the secondary judging module analyzes environmental factors including environmental humidity and environmental temperature during the production of the anti-cracking hollow plates, obtains the environmental humidity and environmental temperature fluctuation of the anti-cracking hollow plates under different processes, judges that the anti-cracking hollow plates in the defect undetermined set have no latent defects if the environmental humidity and the environmental temperature fluctuation are small, and generates a management strategy without management;
If the environmental humidity and the environmental temperature fluctuate greatly, judging that the anti-cracking hollow plates in the broken defect pending set have latent defects, generating a management strategy to be managed, wherein the management strategy is used for controlling the production line to stop running, and generating a management suggestion to an administrator.
In a preferred embodiment, after the production line finishes producing a batch of anti-cracking hollow plates, the management module obtains a non-defective set, a defect pending set or a defect set dividing result of the anti-cracking hollow plates in the batch, and obtains the number of the anti-cracking hollow plates in the non-defective set, the number of the anti-cracking hollow plates in the defect pending set and the number of the anti-cracking hollow plates in the defect set;
the method comprises the steps of weighing the number of the anti-cracking hollow plates in a defect-free set and the number of the anti-cracking hollow plates in a defect-undetermined set, and then generating a management value for a production line, wherein the expression is as follows: Wherein bv x is a management value, and B w、Bd、Bq is the number of the anti-cracking hollow plates in the defect-free set, the number of the anti-cracking hollow plates in the defect-undetermined set and the number of the anti-cracking hollow plates in the defect set respectively;
After the management value of the production line is obtained, the management value is compared with the management threshold, if the management value is larger than or equal to the management threshold, the production line is judged to be required to be managed, and if the management value is smaller than the management threshold, the production line is judged not to be required to be managed.
In the technical scheme, the invention has the technical effects and advantages that:
According to the invention, a plurality of process characteristic data are comprehensively analyzed through a fusion model, a quality amplitude is output for the production process of the anti-cracking hollow plate, a set dividing module divides the anti-cracking hollow plate into a defect-free set, a defect set or a defect set according to the comparison result of the quality amplitude and a gradient threshold value, if the anti-cracking hollow plate is divided into the defect set, a defect judging module analyzes that the anti-cracking hollow plate has a latent defect, automatically controls the production stop of the anti-cracking hollow plate and sends a warning signal to an administrator, if the anti-cracking hollow plate is divided into the defect set, a secondary judging module analyzes environmental factors during the production of the anti-cracking hollow plate, judges whether the anti-cracking hollow plate in the defect set has the latent defect according to the environmental factors, and generates a corresponding management strategy according to the judging result and sends the management strategy to the administrator. The monitoring system can monitor technological parameters in the generation process of the anti-cracking hollow plate and comprehensively analyze whether the anti-cracking hollow plate has a latent defect by combining environmental factors, so that corresponding management is carried out when the anti-cracking hollow plate is found to have the latent defect, and the service life of the anti-cracking hollow plate is effectively ensured.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments described in the present application, and other drawings may be obtained according to these drawings for a person having ordinary skill in the art.
FIG. 1 is a block diagram of a system according to the present invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the system for supervising the production quality of the anti-cracking hollow plate according to the embodiment comprises a monitoring module, a control module, a data acquisition module, a feature extraction module, an analysis module, a set dividing module, a defect judging module, a secondary judging module and a management module;
The monitoring module is used for monitoring each process in real time in the production process of the anti-cracking hollow plate, and sending monitoring data to the control module and the data acquisition module;
Sensor installation-sensors are installed at key points on the production line, which may include temperature sensors, humidity sensors, pressure sensors, flow sensors, etc. to monitor parameters of various process stages.
And data acquisition, namely acquiring data related to the production process in real time by a sensor. This may include the temperature of the raw materials, the homogeneity of the mixture, the pressure and temperature during foaming, the pressure and shape during forming, etc.
And data transmission, namely transmitting the acquired data to a central control module and a data acquisition module through wireless or wired communication means. This may use conventional communication protocols, such as Modbus, profibus, or more advanced internet of things (IoT) technologies.
And real-time monitoring, namely in the control module, analyzing and monitoring the collected data in real time by using a real-time monitoring system. This helps to detect any abnormal situation or potential problem and take corrective action in time.
And the control feedback is that the control module can automatically adjust parameters in the production process according to the real-time monitoring result so as to keep the parameters within the allowable range. For example, the system may adjust the operating parameters of the heating or cooling device when the temperature or pressure exceeds a set point.
And (3) abnormal alarm, namely when the monitoring system detects an abnormal condition, timely giving an alarm to operators. This may be done by displaying on a monitor screen, sounding an alarm or sending a notification, etc.
And the data acquisition module is responsible for storing the monitored data and establishing a historical data record. This helps analyze long-term trends in the production process, formulate improvement strategies, and meet quality control and regulatory requirements.
And the production manager can remotely access the real-time monitoring data and the history record through a cloud platform or other remote monitoring systems so as to monitor the state of the production line at any time and any place and make corresponding decisions.
The control module stops the process when the monitoring index of a certain process step is abnormal, and sends abnormal index information to an administrator, and the administrator manages the process to enable the process to resume the production of the anti-cracking hollow plate after the process is normal;
Monitoring abnormality, namely collecting data of each process step by the control module through the real-time monitoring system. The control module determines a process step as abnormal when its monitored indicator exceeds a predetermined reasonable range or criteria.
Stopping the process, i.e. once the control module detects an abnormality, it will send a stop signal, temporarily interrupting or stopping the current abnormal process step. This may involve shutting down the equipment, cutting off the supply or adjusting process parameters, etc., to prevent continued production of defective products.
And recording the captured abnormal information by the control module, wherein the recorded abnormal information comprises information such as specific position, time, abnormal type, related parameters and the like of the occurrence of the abnormality. This facilitates post hoc analysis, troubleshooting, and preventive measures.
The control module sends notification to the administrator, typically by means of e-mail, short message, mobile phone application, etc. The notification should contain detailed information of the exception so that the administrator can know the nature and severity of the problem.
Alarm system-in some cases, the control module may also trigger the alarm system to draw more attention. This may include audible and visual alarms, warning signs on a monitor screen, etc.
Automatically recording the cause of the shutdown, the control module may automatically record the cause and duration of the shutdown. Such records can be used for traceability and optimization of the production process.
And the administrator intervenes that after the notification of the control module reaches the administrator, the administrator can quickly evaluate the abnormality and take appropriate measures. This may include dispatching maintenance personnel, adjusting equipment, recalibrating parameters, etc.
Manual recovery Once the administrator confirms that the problem has been solved, the process steps may be manually initiated by a control module or other means to restore production to normal.
The abnormal information and the shutdown reasons recorded by the control module can be used for post-hoc analysis so as to find out the root cause of the problem and develop long-term improvement measures.
The data acquisition module is used for acquiring a plurality of technological parameters related to the quality of the finished product of the anti-cracking hollow plate after the anti-cracking hollow plate is produced, and transmitting the plurality of technological parameters to the characteristic extraction module;
And inputting finished product information, namely inputting the finished product information into a data acquisition module by a production system after the production process is finished. This may include basic information on the production time, number of productions, specification model, etc. of each batch.
The method comprises the steps of obtaining production process data, namely obtaining a plurality of process parameters of the anti-cracking hollow plate;
Quality inspection data acquisition, namely acquiring data related to the quality of the anti-cracking hollow plate, such as size, density, hardness, surface flatness and the like, by using quality inspection equipment and sensors. Such data may be entered manually by an automated inspection device or operator.
And (3) surface quality detection, namely acquiring quality information of the surface of the anti-cracking hollow plate by means of a visual detection system and the like, wherein the quality information comprises color, appearance defects, flatness and the like.
Physical property test a series of physical property tests, such as compressive strength, flexural strength, heat conductivity, etc., were performed to evaluate the overall properties of the anti-crack hollow panels.
Environmental suitability test-if applicable, performing an environmental suitability test, for example, a performance test under different temperature and humidity conditions, to ensure that the anti-cracking hollow plate can stably work under various environments.
And (3) recording the acquired quality data of the finished product into a database or other data storage systems, and establishing a detailed production history record.
And (3) carrying out statistical analysis on the recorded data, wherein the statistical analysis comprises calculation of statistical parameters such as average value, standard deviation and the like so as to evaluate the consistency of the stability of the production process and the product quality.
Report generation, namely generating a quality report, and displaying the data of the quality of the finished product and the analysis result in a visual form. This helps the production manager to quickly understand the quality of the product.
And (3) exception handling, namely if an exception is found in the quality inspection of the finished product, triggering an alarm by the data acquisition module, and informing relevant personnel to timely process and correct.
And the data recorded by the data acquisition module can be used for tracing the production information of each batch so as to trace the product and check the problems when the product is needed.
The characteristic extraction module is used for preprocessing a plurality of process parameters and extracting characteristics to obtain process characteristic data, and the process characteristic data is sent to the analysis module;
data cleaning, namely deleting or repairing missing values, abnormal values or error values. This ensures the integrity and accuracy of the data set.
And removing the repeated data, namely removing the repeated data records, and preventing the repeated data from affecting the analysis and modeling process.
Normalization/normalization, namely, normalizing or normalizing the parameters to eliminate the influence of different dimensions and ensure more accurate comparison and analysis between the parameters. For example, Z-score normalization or MinMax normalization is used.
Smoothing-for parameters that may contain noise, smoothing techniques (e.g., moving averages) may be used to reduce the effects of noise, making the trend clearer.
Time series processing-if the data is time series, time series decomposition, hysteresis processing, etc. may be performed to better understand and utilize the time correlation.
Feature engineering-creating new features by combining, converting or extracting original features to capture potential information and improve the performance of modeling.
Outlier processing-for outliers, deletion, correction, or substitution may be selected. Processing outliers helps prevent adverse effects of anomalies on subsequent analysis and modeling.
Binning/discretizing-the continuous parameters are binned or discretized to help capture nonlinear relationships and reduce the sensitivity of the model to outliers.
Data balancing-in some cases, it may be desirable to process unbalanced data sets to ensure that different classes of data get fair weight in modeling.
Processing missing values, namely processing missing values by adopting a filling (such as a mean value, a median value or an interpolation method) or deleting mode, depending on the distribution and characteristics of data.
Data conversion, namely, data of the skew distribution can be considered to be more similar to normal distribution by using a logarithmic transformation, a square root transformation and the like.
Preprocessing a plurality of process parameters, extracting characteristics, and obtaining process characteristic data, wherein the characteristic data comprises mixing track similarity, foam agent amount deviation and structure assignment.
The analysis module is used for comprehensively analyzing a plurality of process characteristic data through the fusion model, outputting quality amplitude values for the production process of the anti-cracking hollow plate, and sending the quality amplitude values to the set dividing module;
substituting the similarity of the mixing track, the deviation of the foaming agent amount and the structural assignment into a fusion model for comprehensive analysis, and outputting the mass amplitude in the production process of the anti-cracking hollow plate, wherein the function expression is as follows:
Wherein zl f is the mass amplitude, JGF is the structure assignment, GJX is the mixing track similarity, FPC is the foam agent amount deviation, alpha, beta and gamma are the structure assignment, the mixing track similarity and the ratio coefficient of the foam agent amount deviation respectively, and alpha, beta and gamma are all larger than 0.
The acquisition logic of the structural amplitude is that the hardening time and the hardening temperature of the anti-cracking hollow plate are acquired in real time in the hardening process of the anti-cracking hollow plate;
When the hardening time is insufficient, the strength of the anti-cracking hollow plate is insufficient, so that the time period when the hardening time exceeds the time period threshold value is marked as a time period standard time period, and the hardening quality of the anti-cracking hollow plate is better in the time period standard time period;
When the hardening temperature is too high or too low, the physical properties of the anti-cracking hollow plate are unstable, so that the quality of the anti-cracking hollow plate is reduced, and therefore, after the real-time temperature of the anti-cracking hollow plate in the hardening process is obtained, the time period that the real-time temperature is not in the preset temperature range is marked as a temperature early warning time period;
and carrying out integral operation on the time length standard period and the temperature early warning period to obtain a structural amplitude, wherein the function expression is as follows: q (t) is the intensity variation of the anti-cracking hollow plate, [ t x,ty ] is the time length standard period, [ t i,tj ] is the temperature early warning period.
The acquisition logic of the similarity of the mixing track is that the real-time motion track of the mixing mechanism is acquired through a positioner arranged in the mixing mechanism in the mixing process;
Acquiring coordinates of preset n sampling points on a real-time motion track of a mixing mechanism, wherein n is more than or equal to 2, n is a positive integer, calculating the similarity between the actual coordinates of each sampling point and corresponding standard coordinates, adding the coordinate similarity of the n sampling points to obtain the similarity of the mixing track, and the function expression is as follows:
Wherein i=1, 2,3,..n, n is the number of sampling points on the real-time motion track of the mixing mechanism, gj i represents the coordinate similarity of the i-th sampling point;
The coordinate similarity calculation expression of the sampling point is as follows: wherein, (x 1,y1) is the actual coordinates of the sampling point and (x 2,y2) is the standard coordinates of the sampling point;
the bigger the similarity of the mixing track is, the more the motion track deviates from the standard track in the process of stirring the raw materials of the anti-cracking hollow plate by the mixing mechanism, the uneven mixing of the raw materials of the anti-cracking hollow plate is easy to cause, and the quality of the finished product of the anti-cracking hollow plate is reduced, specifically:
the components are uneven, if the motion track of the mixing mechanism deviates from the standard track, the raw materials of different parts can be stirred to different degrees, so that the mixing is uneven. This may lead to compositional differences in the final product, affecting the quality consistency of the anti-crack hollow panels.
Uneven density-mixing can affect the distribution of foam in the anti-cracking hollow plate, resulting in uneven plate density. The non-uniform density may lead to inconsistent structural properties of the product in use, reducing overall quality.
Insufficient strength, that is, if the mixing is not uniform, the raw materials in some areas may not be sufficiently mixed, resulting in weak spots in the finished product, and reducing the overall strength of the anti-cracking hollow plate.
Appearance defects, namely uneven mixing can cause color, texture or other appearance defects on the surface of a finished product, thereby affecting the appearance quality of the anti-cracking hollow plate.
Unstable properties-uneven mixing may cause the properties of the anti-crack hollow plate to vary from part to part, such that the product exhibits unstable properties in use.
The calculation logic of the foam agent amount deviation is that the real-time foam agent amount injected into the anti-cracking hollow plate in the foaming process is obtained, the standard foam agent amount is subtracted from the real-time foam agent amount to obtain a difference value, the absolute value of the difference value is taken as the foam agent amount deviation, the larger the foam agent amount deviation is, the larger or smaller the foam agent amount actually injected into the actual anti-cracking hollow plate in the foaming process is indicated, and therefore the quality of a finished product of the anti-cracking hollow plate is reduced, and the method specifically comprises the following steps:
The amount of foaming agent is larger:
Too low a density, too much blowing agent may cause the foam structure of the anti-crack hollow panel to expand too much, resulting in a decrease in the density of the panel. This may lead to a decrease in the strength of the product, affecting its structural properties in use.
The foam cells are uneven, and excessive foaming agent can cause uneven foam cell formation, uneven surface of the plate and influence appearance quality.
The amount of foaming agent is smaller:
too high a density, insufficient foaming dose may result in a hollow panel with a foam structure that is too tight, resulting in an increased density of the panel. This can result in excessive weight of the product, as well as affecting strength and performance.
The compressive strength is reduced, and the insufficient foaming agent may cause the insufficient compressive strength of the hollow plate, thereby affecting the bearing capacity and service life of the product.
Due to the interrelation among the mixing, foaming and hardening processes of the anti-cracking hollow plate, when structural assignment, mixing track similarity or foam agent amount deviation simultaneously develop to a bad trend, but all the structural assignment, mixing track similarity or foam agent amount deviation are not over/under respective preset threshold values, the anti-cracking hollow plate of the finished product can be caused to have latent defects.
The set dividing module is used for dividing the anti-cracking hollow plate into a defect-free set, a defect to-be-determined set or a defect set according to the comparison result of the quality amplitude and the gradient threshold value, and sending the set dividing result to the defect judging module, the secondary judging module and the management module;
according to the functional expression of the mass amplitude, the larger the mass amplitude is, the more easily the anti-cracking hollow plate is subjected to latent defect, so that after the mass assignment is obtained, the obtained mass assignment is compared with a preset gradient threshold value;
The gradient threshold comprises a first defect threshold and a second defect threshold, wherein the first defect threshold is used for judging whether the hidden defect exists in the anti-cracking hollow plate, the second defect threshold is used for judging the severity of the hidden defect of the anti-cracking hollow plate, and the first defect threshold is smaller than the second defect threshold;
if the mass amplitude is smaller than or equal to the first defect threshold value, judging that the anti-cracking hollow plate does not have a latent defect, and scribing the anti-cracking hollow plate into a defect-free set;
If the mass amplitude is larger than the first defect threshold, judging that the crack-proof hollow plate has a latent defect;
If the mass amplitude is larger than the first defect threshold value and the mass amplitude is smaller than or equal to the second defect threshold value, judging that the hidden defect of the anti-cracking hollow plate is small, and scribing the anti-cracking hollow plate into a defect set;
If the mass amplitude is larger than the second defect threshold, judging that the hidden defect of the anti-cracking hollow plate is large, and scribing the anti-cracking hollow plate into the defect set.
The hidden defects of the anti-cracking hollow plates in the defect waiting set are tiny, and the service life of the anti-cracking hollow plates is not necessarily influenced, so that secondary analysis is needed for the anti-cracking hollow plates in the defect waiting set.
The defect judging module is used for analyzing the hidden defect of the anti-cracking hollow plate if the anti-cracking hollow plate is scratched into the defect set, automatically controlling the production stop of the anti-cracking hollow plate and sending a warning signal to an administrator;
and (3) a production stop signal, namely if the anti-cracking hollow plate has a latent defect, the defect judging module sends a production stop signal to a production line, and the production of the anti-cracking hollow plate is stopped immediately.
And (3) alarming to send an alarm signal to the manager to inform the manager that the production of the anti-cracking hollow plate is stopped, and simultaneously providing detailed information about potential defects, so that the manager can process the anti-cracking hollow plate further.
And recording the information of the potential defects, including the type, the position, the occurrence time and the like of the defects, so as to facilitate subsequent quality analysis and tracing.
And safety shutdown, namely ensuring that production equipment is in a safe state during shutdown, and preventing safety problems caused by sudden shutdown.
System recovery-after the administrator confirms and solves the potential defect problem, the system is allowed to resume production, ensuring that the production of the possibly defective anti-crack hollow panel is not continued until the problem is solved.
The secondary judging module is used for analyzing environmental factors when the anti-cracking hollow plates are produced if the anti-cracking hollow plates are marked into the defect set to be determined, judging whether the anti-cracking hollow plates in the defect set to be determined have latent defects or not according to the environmental factors, generating corresponding management strategies according to the judging results and sending the management strategies to an administrator;
analyzing environmental factors including environmental humidity and environmental temperature during production of the anti-cracking hollow plates, acquiring the environmental humidity and environmental temperature fluctuation of the anti-cracking hollow plates under different processes, judging that the anti-cracking hollow plates in the defect undetermined set have no latent defects if the environmental humidity and the environmental temperature fluctuation are small, and generating a management strategy without management;
If the environmental humidity and the environmental temperature fluctuate greatly, judging that the anti-cracking hollow plates in the broken defect pending set have latent defects, generating a management strategy to be managed, wherein the management strategy is used for controlling the production line to stop running, and generating a management suggestion to an administrator.
When the environmental humidity and the environmental temperature fluctuation are large, the quality of the anti-cracking hollow plate is influenced, and the method specifically comprises the following steps:
The foaming process is affected by the fact that the production of anti-cracking hollow panels usually involves a foaming process, whereas fluctuations in humidity and temperature may directly affect the performance of the foaming agent. The change in humidity may cause a change in the moisture content in the raw material, thereby affecting the uniformity of foaming. Fluctuations in temperature may alter the activity of the blowing agent, affecting foam formation.
Cell structure non-uniformity the fluctuation of humidity and temperature may lead to non-uniformity of cell structure inside the anti-cracking hollow plate. An increase in humidity may result in a larger foam cell, while a decrease in humidity may result in a smaller foam cell, affecting the distribution and size of the cells and thus affecting the density and strength of the panel.
Appearance quality problems the fluctuations in humidity and temperature may cause appearance quality problems on the surface of the anti-cracking hollow plate. Changes in humidity may cause water mist or condensation on the surface, and changes in temperature may affect the hardening rate of the sheet material, thereby affecting the flatness of the appearance.
Dimensional and shape changes in the production of anti-crack hollow panels, variations in humidity and temperature can cause dimensional and shape changes in the panels. For example, an increase in humidity may cause the sheet to expand, while a decrease in temperature may cause the sheet to shrink, affecting the final product specifications and geometry.
The management module is used for judging whether the production line is required to be managed after analyzing the aggregate division result of the anti-cracking hollow plates in the batch after the production line finishes producing the anti-cracking hollow plates in the batch, and sending the judgment result to an administrator;
After the production line finishes producing a batch of anti-cracking hollow plates, obtaining a non-defective set, a defect undetermined set or a defect set dividing result of the anti-cracking hollow plates in the batch, and obtaining the number of the anti-cracking hollow plates in the non-defective set, the number of the anti-cracking hollow plates in the defect undetermined set and the number of the anti-cracking hollow plates in the defect set;
the method comprises the steps of weighing the number of the anti-cracking hollow plates in a defect-free set and the number of the anti-cracking hollow plates in a defect-undetermined set, and then generating a management value for a production line, wherein the expression is as follows: Wherein bv x is a management value, and B w、Bd、Bq is the number of the anti-cracking hollow plates in the defect-free set, the number of the anti-cracking hollow plates in the defect-undetermined set and the number of the anti-cracking hollow plates in the defect set respectively;
After the management value of the production line is obtained, the management value is compared with the management threshold, if the management value is larger than or equal to the management threshold, the production line is judged to be required to be managed, and if the management value is smaller than the management threshold, the production line is judged not to be required to be managed.
The supervision flow is as follows:
the method comprises the steps that a supervisory system monitors each process in real time in the production process of the anti-cracking hollow plates, when monitoring indexes of a certain process step are abnormal, the supervisory system stops the process and sends abnormal index information to an administrator, the administrator manages the process to enable the production of the anti-cracking hollow plates to continue after the process is recovered to be normal, after the production of the anti-cracking hollow plates is completed, a plurality of process parameters related to the quality of finished products of the anti-cracking hollow plates are obtained, after the process parameters are preprocessed and the process characteristic data are obtained through extracting the characteristics, the process characteristic data are comprehensively analyzed through a fusion model, quality amplitude values are output for the production process of the anti-cracking hollow plates, the anti-cracking hollow plates are marked into a defect-free set, a defect to-be-determined set or a defect set according to the comparison result of the quality amplitude and a gradient threshold, if the anti-cracking hollow plates are marked into the defect set, the anti-cracking hollow plates are analyzed to have latent defects, the supervisory system automatically controls the production of the anti-cracking hollow plates to stop, if the anti-cracking hollow plates are marked into the defect to be determined set, environmental factors related to the quality of the anti-cracking hollow plates are obtained, environmental factors when the anti-cracking hollow plates are produced are combined, the environmental factors are combined with the environmental factors are judged to judge whether the corresponding defect sets are marked into the corresponding hollow plates to be marked when the anti-cracking hollow plates are marked by the manager, and the production line is required to be marked by the manager, and the production results are judged to be marked by the manager after the manager and the quality is judged to have the corresponding quality results.
According to the application, a plurality of process characteristic data are comprehensively analyzed through a fusion model, a quality amplitude is output for the production process of the anti-cracking hollow plate, a set dividing module divides the anti-cracking hollow plate into a defect-free set, a defect set or a defect set according to the comparison result of the quality amplitude and a gradient threshold value, if the anti-cracking hollow plate is divided into the defect set, a defect judging module analyzes that the anti-cracking hollow plate has a latent defect, automatically controls the production stop of the anti-cracking hollow plate and sends a warning signal to an administrator, if the anti-cracking hollow plate is divided into the defect set, a secondary judging module analyzes environmental factors during the production of the anti-cracking hollow plate, judges whether the anti-cracking hollow plate in the defect set has the latent defect according to the environmental factors, and generates a corresponding management strategy according to the judging result and sends the management strategy to the administrator. The monitoring system can monitor technological parameters in the generation process of the anti-cracking hollow plate and comprehensively analyze whether the anti-cracking hollow plate has a latent defect by combining environmental factors, so that corresponding management is carried out when the anti-cracking hollow plate is found to have the latent defect, and the service life of the anti-cracking hollow plate is effectively ensured.
The above formulas are all formulas with dimensions removed and numerical values calculated, the formulas are formulas with a large amount of data collected for software simulation to obtain the latest real situation, and preset parameters in the formulas are set by those skilled in the art according to the actual situation.
It should be understood that the term "and/or" is merely an association relationship describing the associated object, and means that three relationships may exist, for example, a and/or B, and may mean that a exists alone, while a and B exist alone, and B exists alone, wherein a and B may be singular or plural. In addition, the character "/" herein generally indicates that the associated object is an "or" relationship, but may also indicate an "and/or" relationship, and may be understood by referring to the context.
It should be understood that, in various embodiments of the present application, the sequence numbers of the foregoing processes do not mean the order of execution, and the order of execution of the processes should be determined by the functions and internal logic thereof, and should not constitute any limitation on the implementation process of the embodiments of the present application.
Those of ordinary skill in the art will appreciate that the various illustrative elements and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, or combinations of computer software and electronic hardware. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the solution. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present application. It will be clear to those skilled in the art that, for convenience and brevity of description, specific working procedures of the above-described systems, apparatuses and units may refer to corresponding procedures in the foregoing method embodiments, and are not repeated herein.
The foregoing is merely illustrative of the present application, and the present application is not limited thereto, and any person skilled in the art will readily recognize that variations or substitutions are within the scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
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