CN117075568A - Batching control system based on continuous monitoring - Google Patents
Batching control system based on continuous monitoring Download PDFInfo
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- CN117075568A CN117075568A CN202311346334.XA CN202311346334A CN117075568A CN 117075568 A CN117075568 A CN 117075568A CN 202311346334 A CN202311346334 A CN 202311346334A CN 117075568 A CN117075568 A CN 117075568A
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 71
- 238000002347 injection Methods 0.000 claims abstract description 112
- 239000007924 injection Substances 0.000 claims abstract description 112
- 239000000463 material Substances 0.000 claims abstract description 90
- 230000003993 interaction Effects 0.000 claims abstract description 22
- 238000004458 analytical method Methods 0.000 claims description 3
- 238000004364 calculation method Methods 0.000 claims description 3
- 239000004615 ingredient Substances 0.000 abstract description 4
- 238000005303 weighing Methods 0.000 description 55
- 238000000034 method Methods 0.000 description 10
- 230000008569 process Effects 0.000 description 7
- 239000002994 raw material Substances 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 150000001875 compounds Chemical class 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000012937 correction Methods 0.000 description 2
- 238000013016 damping Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000013459 approach Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000003814 drug Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000010137 moulding (plastic) Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
Classifications
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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]
- G05B19/41865—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 job scheduling, process planning, material flow
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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
- G05B2219/32252—Scheduling production, machining, job shop
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- General Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The application relates to the field of batching control systems, in particular to a batching control system based on continuous monitoring, which comprises a control terminal, and a man-machine interaction module, a feeding module and a monitoring module which are connected with the control terminal in a signal manner; the man-machine interaction module is used for inputting instructions and outputting parameters; the control terminal responds to an instruction input into the man-machine interaction module and controls the feeding module to fill materials into the monitoring module according to a preset injection amount; the monitoring module continuously monitors the actual injection quantity of the material and feeds back the actual injection quantity to the control terminal; and the control terminal controls the feeding module to stop filling under the condition that the actual injection quantity is equal to the preset injection quantity. The proportion of the materials actually injected into the monitoring module is accurate, and the accurate proportion of ingredients is ensured.
Description
Technical Field
The application relates to the field of batching control systems, in particular to a batching control system based on continuous monitoring.
Background
In the production process of plastic molding processing, food and medicine production and other industries, raw materials are required to be proportioned according to preset proportion, and then a series of production process are carried out to finally form the product. However, in the actual operation process of ingredients, the injection quantity of each raw material is usually controlled manually, and deviation of the injection quantity of the raw material due to manual operation errors often occurs, so that the deviation of the preset proportion is caused; under the condition of deviating from the preset proportion, the material needs to be manually filled to reach the preset proportion, and the batching efficiency is low.
Therefore, it is needed to develop a batch control system capable of controlling the feeding module to inject materials according to the preset injection amount and the preset injection amount according to the input preset proportion, and controlling the feeding module to perform material filling when the actual injection amount deviates from the preset proportion based on the continuously monitored actual injection amount, so as to ensure that the raw materials are accurately injected according to the preset proportion.
Disclosure of Invention
The application aims to provide a batching control system based on continuous monitoring, which can at least partially overcome the technical problems, and is characterized in that a feeding module is automatically controlled to perform material injection, so that accurate material injection according to a preset injection amount is realized, and when the actual injection amount deviates to cause that the actual material proportion is inconsistent with the preset material proportion, the feeding module is automatically controlled to perform material supplementary injection, so that the actual material proportion is consistent with the preset material proportion.
The application provides a continuous monitoring-based batching control system, which comprises a control terminal, a man-machine interaction module, a feeding module and a monitoring module, wherein the man-machine interaction module, the feeding module and the monitoring module are connected with the control terminal in a signal manner; the man-machine interaction module is used for inputting instructions and outputting parameters; the control terminal responds to an instruction input into the man-machine interaction module and controls the feeding module to fill materials into the monitoring module according to a preset injection amount; the monitoring module continuously monitors the actual injection quantity of the material and feeds back the actual injection quantity to the control terminal; and the control terminal controls the feeding module to stop filling under the condition that the actual injection quantity is equal to the preset injection quantity.
Further, the instructions input into the man-machine interaction module comprise preset proportions and preset injection amounts of materials; the parameters output by the man-machine interaction module comprise the actual injection quantity and the actual proportion of the materials.
Further, the controlling the feeding module to fill the monitoring module with the material according to the preset injection amount includes: and controlling the feeding module to fill different materials into the monitoring module one by one according to respective preset injection amounts.
Further, after the feeding module stops filling, the control terminal calculates the actual proportion of the materials injected into the monitoring module; under the condition that the actual proportion is inconsistent with the preset proportion, the control terminal calculates the supplementary injection quantity of the material to be supplementary injected, and controls the feeding module to carry out material supplementary injection according to the supplementary injection quantity; and under the condition that the actual proportion is consistent with the preset proportion, the control terminal controls the monitoring module to output materials.
Further, the control terminal is composed of a controller for receiving data and issuing control instructions and an industrial control computer for analysis and calculation.
Compared with the prior art, the application has the following advantages and beneficial effects:
1. according to the weighing compound system provided by the embodiment of the application, the actual injection quantity of the material at the current moment can be obtained by continuously monitoring the injection quantity of the material through the monitoring module; the actual injection quantity of the material is fed back to the control terminal, so that the control terminal can timely control the feeding module to stop filling under the condition that the actual injection quantity of the material is equal to the preset injection quantity, the accuracy of the proportion of the material actually injected into the monitoring module is facilitated, and the accuracy of the proportion of ingredients is ensured;
2. according to the weighing compound system provided by the embodiment of the application, the plurality of uniformly distributed first weighing sensors are arranged below the accommodating cavity, so that the influence of unbalanced load caused by uneven distribution of weighing objects on a weighing result can be reduced; three or more first weighing sensors are on the same horizontal plane, so that the stability of the weighing system can be maintained to a certain extent, and the interference of environmental vibration is reduced; the plurality of first weighing sensors are used for weighing preset measuring ranges, and the measuring range of each first weighing sensor is smaller than the measuring range required by measuring by using one weighing sensor, so that the result precision of the actual injection quantity finally measured by the monitoring module is higher;
3. according to the weighing compound system provided by the embodiment of the application, the second weighing sensors which are in one-to-one correspondence with the first weighing sensors are arranged, the influence of vibration on the weighing sensors is reflected by the proportion of the measured value of the second weighing sensors to the true value, the actual injection quantity is compensated, and the weighing error of the vibration on each first weighing sensor is eliminated;
4. according to the weighing compound system provided by the embodiment of the application, the control module is used for controlling the feeding module to carry out the supplementary injection according to the injection mass flow before the material stops being injected and the supplementary injection quantity of the material, so that the proportion correction after the material injection can be realized, the actual injection proportion of each material is more approximate to the preset injection proportion, and the batching result is more accurate.
Drawings
The accompanying drawings, which are included to provide a further understanding of embodiments of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the principles of the application. In the drawings:
FIG. 1 is a block diagram of a continuous monitoring based dosing control system according to an embodiment of the present application;
FIG. 2 is a schematic diagram of a hardware configuration of a continuous monitoring based batch control system according to an embodiment of the present application;
FIG. 3 is a schematic diagram of a hardware structure of a monitoring module according to an embodiment of the application;
FIG. 4 is a schematic diagram of a hardware structure of another monitoring module according to an embodiment of the application;
FIG. 5 is an enlarged schematic view of a portion of the area A shown in FIG. 4;
FIG. 6 is a schematic diagram of a hardware structure of a monitoring module according to an embodiment of the application;
fig. 7 is a flow chart of the control terminal performing material refilling after the feeding module stops filling according to the embodiment of the application.
In the drawings, the reference numerals and corresponding part names:
1-a control terminal; 2-a man-machine interaction module; 3-a feeding module; 4-a monitoring module; 401-accommodating chambers; 402-a first load cell; 403-matrix; 404-a second load cell; 405-loading; 406-a mounting ring; 407-damping.
Detailed Description
For the purpose of making apparent the objects, technical solutions and advantages of the present application, the present application will be further described in detail with reference to the following examples and the accompanying drawings, wherein the exemplary embodiments of the present application and the descriptions thereof are for illustrating the present application only and are not to be construed as limiting the present application. It should be noted that the present application is already in a practical development and use stage.
In order to overcome the defects that in the actual operation process of the existing ingredients, the injection quantity of each raw material is usually controlled manually, and deviation of the injection quantity of the raw material is often caused by manual operation errors, so that the deviation of the preset proportion is caused; under the condition of deviating from the preset proportion, the material needs to be manually filled to reach the preset proportion, and the batching efficiency is low. The application provides a batching control system based on continuous monitoring, which is used for at least partially overcoming the technical problems and realizing the beneficial effects.
Example 1:
as shown in fig. 1, the batching control system based on continuous monitoring provided by the embodiment of the application comprises a control terminal 1, and a man-machine interaction module 2, a feeding module 3 and a monitoring module 4 which are in signal connection with the control terminal 1; the man-machine interaction module 2 is used for inputting instructions and outputting parameters; the control terminal 1 responds to an instruction input to the man-machine interaction module 2, and controls the feeding module 3 to charge materials into the monitoring module 4 according to a preset injection amount; the monitoring module 4 continuously monitors the actual injection amount of the material and feeds back the actual injection amount to the control terminal 1; and the control terminal 1 controls the feeding module 3 to stop filling under the condition that the actual injection amount is equal to the preset injection amount.
The instructions input into the man-machine interaction module 2 comprise preset proportions and preset injection amounts of materials; the parameters output by the man-machine interaction module 2 comprise the actual injection quantity and the actual proportion of the materials; the controlling the feeding module 3 to fill the monitoring module 4 with the material according to the preset injection amount comprises: controlling the feeding module 3 to fill different kinds of materials into the monitoring module 4 one by one according to respective preset injection amounts; the control terminal 1 is composed of a controller for receiving data and issuing control instructions, and an industrial control computer for analysis and calculation. Preferably, the controller is a self-developed controller of my department, and it should be understood that a commercially available PLC controller can also be used as the controller. The batching control system based on continuous monitoring provided by the embodiment of the application can be used for controlling the batching system shown in fig. 2 to accurately batching various materials according to preset proportions, and in the batching system shown in fig. 2, the control terminal 1 comprises a controller and an industrial control computer which are packaged in a side box body of the batching system; the man-machine interaction module 2 is a touch display screen and can be used for inputting instructions and display parameters; the feeding module 3 is a combined storage hopper and comprises a plurality of storage compartments, each compartment is respectively filled with a material, the material is fed to the monitoring module under the control of the control terminal 1, the monitoring module 4 is located below the feeding module 3, the weight of the material input by the feeding module 3 is continuously monitored, and the weight of each component material can be calculated by calculating the difference value.
Based on the above, according to the batching control system based on continuous monitoring provided by the embodiment of the application, the actual injection quantity of the material at the current moment can be obtained by continuously monitoring the injection quantity of the material through the monitoring module 4; by feeding back the actual injection quantity of the material to the control terminal 1, the control terminal 1 can timely control the feeding module 3 to stop filling under the condition that the actual injection quantity of the material is equal to the preset injection quantity, so that the actual injection quantity of the material is equal to the preset injection quantity, the accuracy of the proportion of the material actually injected into the monitoring module 4 is facilitated, and the accuracy of the batching proportion is ensured.
Preferably, as shown in fig. 3, the monitoring module 4 includes a housing cavity 401 (preferably, the housing cavity 401 is funnel-shaped, the material entering the monitoring module 4 is distributed more uniformly in the funnel-shaped housing cavity 401), and at least three first weighing sensors 402, each first weighing sensor 402 is uniformly distributed below the housing cavity 401 and is used for measuring the weight of the housing cavity 401 and the injected material, each first weighing sensor 402 is connected to the control terminal 1 in a signal manner, the control terminal 1 converts the electric signal fed back by each first weighing sensor 402 into a weighing value, and the actual injection amount is equal to the sum of the weighing values of each first weighing sensor 402 minus the weight of the housing cavity 401. Based on this, by arranging a plurality of uniformly distributed first weighing sensors 402 below the accommodating cavity 401, the influence of unbalanced load caused by uneven distribution of the weighing objects on the weighing result can be reduced, so that the actual injection amount measured by the monitoring module 4 is more accurate; three or more first load cells 402 define a plane (preferably on the same horizontal plane) that can maintain the balance of the weighing system itself to a certain extent, reducing the interference of the environmental vibrations received; the multiple first weighing sensors 402 are used for weighing a preset measuring range, so that the measuring range of each first weighing sensor 402 can be slightly smaller (the measuring range is smaller than that of the condition that one weighing sensor is used for weighing the accommodating cavity 401 and the injected material), and the precision of the first weighing sensor 402 with the small measuring range is higher, so that the result precision of the actual injected quantity finally measured by the monitoring module 4 is higher; the higher the accuracy of the actual injection quantity finally measured by the monitoring module 4, the smaller the deviation of the actual proportion of the material finally injected into the monitoring module 4 from the preset proportion, the control terminal 1 controls the feeding module 3 to stop injection based on the accuracy.
However, during operation of the apparatus, the apparatus is affected by vibration caused by operation of the motor or the like, which causes the sum of the weighing values of the first load cells 402 to be unequal to the sum of the weight of the accommodating chamber 401 and the actual injection amount. Therefore, it is necessary to eliminate the weighing error due to vibration.
More preferably, as shown in fig. 4 to 5, the monitoring module 4 further includes second weighing sensors 404 corresponding to the first weighing sensors 402 one by one, the second weighing sensors 404 and the first weighing sensors 402 are mounted on the same substrate 403, and each second weighing sensor 404 is connected to a load 405 with a preset mass; each of the second weighing sensors 404 is connected to the control terminal 1 in a signal manner, and the control terminal 1 obtains a vibration compensation coefficient in response to the signal sent by each of the second weighing sensors 404 and compensates the actual injection amount measured by each of the first weighing sensors 402 according to the vibration compensation coefficient. Wherein the vibration compensation coefficient is obtained by:
in the method, in the process of the application,Afor the vibration compensation coefficient, m 1 、m 2 、m 3 、…、m n For each second load cell 404 measurement value, m 0 For the weight of the load 405 of a preset mass,nis the number of second load cells 404.
The compensation of the actual injection amount measured by each of the first load cells 402 according to the vibration compensation coefficient is performed by:
the actual injection amount after compensation is obtained:
in the method, in the process of the application,M Z in order to compensate for the actual injection quantity after compensation,M R to accommodate the weight of the cavity 401, M 1 、M 2 、M 3 、…、M i For each first load cell 402 measurement,iis the number of first load cells 402.
Based on this, by providing the second weighing sensors 404 in one-to-one correspondence with the first weighing sensors 402, the influence of the vibration on the weighing sensors is reflected by the ratio (vibration compensation coefficient) of the measured value and the actual value of the second weighing sensors 404, and the actual injection amount is compensated, so that the weighing error caused by the vibration on each first weighing sensor 402 is eliminated, which is beneficial to making the accuracy of the result of the actual injection amount finally measured by the monitoring module 4 higher; the higher the accuracy of the actual injection quantity finally measured by the monitoring module 4, the smaller the deviation of the actual proportion of the material finally injected into the monitoring module 4 from the preset proportion, the control terminal 1 controls the feeding module 3 to stop injection based on the accuracy.
More preferably, as shown in fig. 6, a mounting ring 406 is further disposed below the accommodating cavity 401, and the mounting ring 406 is connected to the accommodating cavity 401 through a plurality of dampers 407; each of the first force sensors is disposed below the mounting ring 406. Based on this, the measured values of the first force sensors are the weights of the accommodating cavity 401, the mounting ring 406, the plurality of dampers 407 and the injected material, and by setting the plurality of dampers 407, the impact of the injected material on the accommodating cavity 401 in the material injection process can be eliminated, so that the error of the weighing value of each first weighing sensor 402 caused by impact force is avoided; in addition, the damping 407 can also reduce the influence of vibration on each first weighing sensor 402 during the operation of the device.
Example 2:
in the process of actual batching, the material is injected into the monitoring module 4 from the feeding module 3, the injection amount of the material measured by the monitoring module 4 does not comprise the empty material (i.e. the material in the air which does not reach the accommodating cavity 401 of the monitoring module 4 after leaving the feeding module 3), so the control terminal 1 controls the monitoring module 4 to stop injection according to the fact that the actual injection amount detected by the monitoring module 4 is equal to the preset injection amount, and finally, the injection amount of each material is larger than the injection amount measured at the moment of stopping injection, and therefore, the proportion of the actual injection material still has deviation from the preset proportion.
In order to make the actual proportion of the material actually injected into the accommodating cavity 401 approach to the preset proportion, as shown in fig. 7, the continuous monitoring-based batching control system provided in this embodiment further includes, after the feeding module 3 stops filling, the control terminal 1 calculates the actual proportion of the material injected into the monitoring module 4;
under the condition that the actual proportion is inconsistent with the preset proportion, the control terminal 1 calculates the supplementary injection quantity of the material to be supplementary injected, and controls the feeding module 3 to carry out material supplementary injection according to the supplementary injection quantity;
and under the condition that the actual proportion is consistent with a preset proportion, the control terminal 1 controls the monitoring module 4 to output materials.
Wherein, the controlling the feeding module 3 to carry out material refill according to the refill amount comprises:
the control terminal 1 calculates the injection mass flow before stopping the injection of the material according to the material increment after stopping the injection and the time corresponding to the material increment, which are monitored by the monitoring module 4;
the control terminal 1 calculates the filling duration according to the filling quantity and the filling mass flow;
and the control terminal 1 controls the feeding module 3 to carry out material supplementary injection according to the supplementary injection duration, wherein the supplementary injection mass flow is the injection mass flow before stopping injection.
Based on the method, the control module controls the feeding module 3 to carry out supplementary injection according to the supplementary injection duration according to the injection mass flow before the material stops being injected and the supplementary injection quantity of the material, so that the proportion correction after the material injection can be realized; the actual injection proportion of each material can be more approximate to the preset injection proportion by carrying out supplementary injection on each material, so that the batching result is more accurate; the automatic control of the whole process of batching can be realized through the batching control system based on continuous monitoring, and the batching result is accurate.
The foregoing description of the embodiments has been provided for the purpose of illustrating the general principles of the application, and is not meant to limit the scope of the application, but to limit the application to the particular embodiments, and any modifications, equivalents, improvements, etc. that fall within the spirit and principles of the application are intended to be included within the scope of the application.
Claims (5)
1. The batching control system based on continuous monitoring is characterized by comprising a control terminal (1), a man-machine interaction module (2), a feeding module (3) and a monitoring module (4), wherein the man-machine interaction module (2), the feeding module (3) and the monitoring module (4) are in signal connection with the control terminal (1);
the man-machine interaction module (2) is used for inputting instructions and outputting parameters;
the control terminal (1) responds to an instruction input into the man-machine interaction module (2) and controls the feeding module (3) to fill materials into the monitoring module (4) according to a preset injection amount;
the monitoring module (4) continuously monitors the actual injection quantity of the material and feeds back the actual injection quantity to the control terminal (1); the control terminal (1) controls the feeding module (3) to stop filling under the condition that the actual injection amount is equal to the preset injection amount.
2. The dosing control system according to claim 1, characterized in that the instructions input to the man-machine interaction module (2) comprise a preset proportion of material and a preset injection quantity; the parameters output by the man-machine interaction module (2) comprise the actual injection quantity and the actual proportion of the materials.
3. The dosing control system according to claim 1, characterized in that said controlling said feeding module (3) to fill said monitoring module (4) with material according to a preset injection quantity comprises: the feeding module (3) is controlled to fill different kinds of materials into the monitoring module (4) one by one according to respective preset injection amounts.
4. The dosing control system according to claim 2, characterized in that the control terminal (1) calculates the actual proportion of material injected into the monitoring module (4) after the feeding module (3) has stopped filling;
under the condition that the actual proportion is inconsistent with the preset proportion, the control terminal (1) calculates the supplementary injection quantity of the material to be supplementary injected, and controls the feeding module (3) to carry out material supplementary injection according to the supplementary injection quantity;
and under the condition that the actual proportion is consistent with the preset proportion, the control terminal (1) controls the monitoring module (4) to output materials.
5. The dosing control system according to claim 1, characterized in that the control terminal (1) consists of a controller for receiving data and issuing control instructions and an industrial control computer for analysis and calculation.
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| CN202311346334.XA CN117075568B (en) | 2023-10-18 | 2023-10-18 | Batching control system based on continuous monitoring |
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