CN201179725Y - Intelligentized control system for wall thickness of extrusion-blow molding product based on image recognition technique - Google Patents
Intelligentized control system for wall thickness of extrusion-blow molding product based on image recognition technique Download PDFInfo
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- CN201179725Y CN201179725Y CNU2008200448357U CN200820044835U CN201179725Y CN 201179725 Y CN201179725 Y CN 201179725Y CN U2008200448357 U CNU2008200448357 U CN U2008200448357U CN 200820044835 U CN200820044835 U CN 200820044835U CN 201179725 Y CN201179725 Y CN 201179725Y
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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
- Y02P80/00—Climate change mitigation technologies for sector-wide applications
- Y02P80/10—Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
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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
- Y02P80/00—Climate change mitigation technologies for sector-wide applications
- Y02P80/40—Minimising material used in manufacturing processes
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Abstract
The utility model provides an on-line control system for the thickness of extrusion blow-molded product wall based on an image recognition technology, which comprises a parison wall thickness on-line detection module, an industrial control processing module and a die orifice clearance control module; the parison wall thickness on-line detection module is connected with the industrial control processing module; and the industrial control processing module is connected with the die orifice clearance control module. The on-line control system is stable, simple in operation, easy to realize and low in cost, has the advantages of carrying out real-time measurement, feedback, regulation and control, improving product performance, reducing material consumption and ensuring product performance, can be conveniently applied to the technical reconstruction of the prior blow molding equipment and remarkably improves the performance and the qualification rate of a blow-molded product.
Description
Technical field
The utility model relates to plastics extrusion blow molding product wall thickness control technology, particularly a kind of extrusion-blow molding product wall thickness on-line control system based on image recognition technology.
Background technology
The plastics blow molding product wall thickness is crossed conference and is caused the overweight and unnecessary waste of material of goods, and reduces production efficiency; The too small goods mechanical property that then can cause of wall thickness can not satisfy designing requirement.At present, adopt the method that the system of parison wall thickness cyclelog is installed on extrusion blow molding machine to realize control in the industrial production to the blow-molded article wall thickness.The system of parison wall thickness cyclelog moves up and down to change head die orifice gap length a head plug or a mouthful mould by electrohydraulic servo system, distributes thereby obtain required system of parison wall thickness, and the blow-molded article Thickness Distribution is met the demands.Yet, existing various inner parameters in the blowing process of reality inevitably changes and external disturbance, variation as supply voltage, melt temperature, hydraulic system etc. causes the fluctuation in head gap, cause actual wall thickness of goods and target wall thickness to have bigger deviation, the result causes that the product percent defective is higher, the unsettled phenomenon of quality.Therefore, need carry out On-line Control, make the blow-molded article wall thickness meet the demands the blow-molded article wall thickness.
The extrusion-blown modling process generally comprises three phases, i.e. the cooling curing of parison formation, preform blowup and goods.Parison formation has crucial meaning as first stage of whole process.The size of parison directly determines the size and the performance of end article in this stage.Therefore, consistent if the system of parison wall thickness of moulding distributes in the extrusion-blown modling process with the desired system of parison wall thickness distribution of moulded products, can guarantee that then the Thickness Distribution of resulting product meets the demands.Therefore, for extrusion-blow molding product wall thickness distribution wall thickness On-line Control, can control the Thickness Distribution of goods indirectly by control parison Thickness Distribution.
Can utilize the online system of parison wall thickness of obtaining of image recognition technology to distribute, specifically: adopt video camera to take the exterior contour of parison, on parison, make marks at interval with certain hour with scriber simultaneously, the diameter that can determine parison by graphical analysis distributes, by some simple hypothesis, calculate the Thickness Distribution of parison again.This theoretical method is simple, and experimental provision is simple and easy.But this technology only is used to measure that system of parison wall thickness distributes and diameter distributes at present, and it is open not see that the technology of FEEDBACK CONTROL (promptly the head die gap being controlled) is carried out in the system of parison wall thickness distributed intelligence that utilizes image recognition to obtain in real time.
The utility model content
The purpose of this utility model is to overcome the shortcoming of existing blow-molded article wall thickness control technology, provide a kind of and can carry out On-line Control product wall thickness, guarantee product quality, make and produce the extrusion-blow molding product wall thickness on-line control system stable, that product percent of pass is high based on image recognition technology.
The purpose of this utility model is achieved through the following technical solutions: a kind of extrusion-blow molding product wall thickness on-line control system based on image recognition technology, comprise the online detection module of system of parison wall thickness, industry control processing module, die gap control module, the online detection module of described system of parison wall thickness is connected with the industry control processing module, and described industry control processing module is connected with the die gap control module.
The online detection module of described system of parison wall thickness comprises: rotation-speed measuring device, scriber, video camera, image pick-up card, photoelectric sensor, described video camera is connected with image pick-up card, described image pick-up card, rotation-speed measuring device, scriber, photoelectric sensor are connected with the industry control processing module, and described industry control processing module is equipped with image analysis software.
Described video camera is installed in the below of extruder head, and its camera lens and parison intermediate point are on same horizontal plane, and be and vertical with the head center line, with the distance of center line be 40～50cm, described video camera is connected with image pick-up card.
Described scriber is installed in the position of the below 2～3cm of extruder head, scriber can be along the horizontal direction adjusting position, scriber links to each other with the horizontal direction adjusting part, and described scriber also is connected with industrial computer by the RS232 serial ports, can control the frequency of ink marks by industrial computer.
Described rotation-speed measuring device is connected with industrial computer by the RS232 serial ports, is used to detect the rotating speed of parison extrusion screw rod, thereby can obtain to extrude accurately flow.Described rotation-speed measuring device is optional, and to hold up the model that meter electronics Co., Ltd of section produces with Shanghai be the multi-functional speed-frequency measuring instrument of MFT.
Described photoelectric sensor is installed in the head below, and its light path intersects with the head center line and be vertical with it, and its concrete setting height(from bottom) is determined by required parison length; Described photoelectric sensor also is connected with industrial computer by the RS232 serial ports, be used to detect parison length, when parison arrives certain-length is that photoelectric sensor will send signal and give the industry control processing module, carry out the IMAQ that parison formation was processed and carried out in follow-up blowing.
Described industry control processing module comprises industrial computer, Programmable Logic Controller, output port, many serial port expanding modules, described Programmable Logic Controller is connected with industrial computer by output port, and described industrial computer also is connected with other external equipment (as: display) by output port; Described industrial computer is equipped with image analysis software.
Described die gap control module comprises system of parison wall thickness control panel, servo valve and hydraulic system, and described system of parison wall thickness control panel is connected with servo valve, and described servo valve is connected with hydraulic system.
A kind of extrusion-blow molding product wall thickness On-Line Control Method of utilizing said system to realize comprises the steps:
(1) according to the specifically Thickness Distribution requirement of blow-molded article, obtain required head die gap curve by debugging repeatedly, make final wall thickness meet the requirement of target wall thickness, start the online detection module of system of parison wall thickness then, by the online Thickness Distribution data of obtaining parison of image recognition technology, this system of parison wall thickness distributed data will be as the target parison Thickness Distribution of blowing.
(2) the head die gap curve with gained in the step (1) is input to the industry control processing module as initial value, and regulates the die gap control module by the industry control processing module, and the head die gap is controlled, and carries out blow molding operation.
(3) in the blowing process, the online detection module of system of parison wall thickness obtains the wall thickness data of extruded parisons automatically, then the system of parison wall thickness feedback information that is obtained is stored to the industry control processing module.
(4) difference degree of the target parison Thickness Distribution curve of gained in the system of parison wall thickness distribution curve of analyzing and testing and the step (1), and the fuzzy Iterative Learning Control Algorithm of startup obtains revised head die gap curve, revised head die gap curve is input to industry control processing module and die gap control module, adjusting head die gap carries out blow molding operation next time, meets the demands up to the extruded parisons wall thickness.
Described step (1) specifically can be: to a blow-molded article that has particular wall thickness to require, according to its Thickness Distribution data, make final wall thickness meet the requirement of target wall thickness by debugging repeatedly, after acquisition meets the blow-molded article of target wall thickness requirement, in order to obtain the system of parison wall thickness distributed data of this moment, the wall thickness control system starts the online detection module of system of parison wall thickness, rotation-speed measuring device begins to measure screw speed, and rotating speed is transferred to industrial computer by the RS232 serial ports, when extruded parisons arrives the photoelectric sensor position, start the camera photography system, and give industrial computer with the image real-time Transmission by image pick-up card, analysis software will be discerned gathering the image of returning, and obtain the external diameter of parison, internal diameter, and the data such as Thickness Distribution of parison.
Described step (3) specifically can be: when extruding beginning, rotation-speed measuring device just begins to measure screw speed, and rotating speed is transferred to industrial computer by the RS232 serial ports, the industry control processing module will write down the screw speed of different time, start scriber simultaneously, rule at interval according to certain hour, when extruded parisons arrives the photoelectric sensor position, start the camera photography system, and give industrial computer with the image real-time Transmission by image pick-up card, utilize image process method can obtain the external diameter of parison, just can calculate the internal diameter and the Thickness Distribution of parison again according to mass conservation law.
In the described step (4), so-called fuzzy Iterative Learning Control Algorithm is on the basis of iterative learning control, increases a fuzzy control link.The main method of setting up fuzzy control rule is as follows: if wall thickness deflection is positive, and the trend of increase is arranged, wall thickness change is for negative big so; If wall thickness deflection just is, and the trend that reduces is arranged, wall thickness change is for negative little so; If wall thickness deflection is negative, and the trend of increase is arranged, wall thickness change is honest so; If wall thickness deflection is negative, and the trend that reduces is arranged, wall thickness change is for just little so.
Action principle of the present utility model is: in the blowing production process of reality, existing various inner parameters inevitably changes and external disturbance, variation as supply voltage, melt temperature, hydraulic system etc. causes the fluctuation in head gap, make system of parison wall thickness distribute and there is bigger deviation in desired value, thereby cause product wall thickness and target wall thickness inconsistent.This moment must corresponding adjusting head gap variation of the blow-molded article wall thickness of appearance because disturb to remedy in actual production process.Product wall thickness is carried out On-line Control, need the online procedure parameter that obtains reflection blow-molded article wall thickness, because the Thickness Distribution of goods mainly by the Thickness Distribution decision of parison before the inflation, therefore, can be controlled pairing product wall thickness indirectly by control parison Thickness Distribution and distribute.Can utilize the online system of parison wall thickness of obtaining of image recognition technology to distribute, specifically: rule at interval with certain hour with scriber, adopt video camera to take the exterior contour of parison simultaneously, the diameter that can determine parison by graphical analysis distributes, and just can calculate the internal diameter and the Thickness Distribution of parison again according to mass conservation law.From adjustment process, be the height non-linear relation between control variables (die gap change curve) and the control target (system of parison wall thickness distribution), it is a kind of non-linear, strongly coupled system, therefore, adopt conventional control method effect undesirable, the utility model adopts the algorithm of fuzzy iterative learning control, iterative learning control is combined with fuzzy control, give full play to both advantages, quicken the speed of iterative learning, avoided the slow shortcoming of traditional Iterative Learning Control Algorithm convergence rate effectively.
The utility model has following advantage and effect with respect to prior art:
(1) measures feedback regulation control in real time, enhance product performance and reduce material consumption.The utility model carries out On-line Control to the blowing process can overcome product wall thickness deviation because of various inner parameters change and external disturbance causes.By system of parison wall thickness is carried out online detection, and the control algolithm of combined with intelligentization, head die gap curve is carried out feedback regulation control, the blow-molded article wall thickness is come back in the predetermined claimed range.Therefore, utilize the utility model can enhance product performance, reduce material consumption, reduce percent defective.
(2) utilize the utility model that system of parison wall thickness is carried out online detection, can guarantee that properties of product are stable.In the blowing production process, traditional method of quality control is to adopt test check, and a certain amount of goods of promptly every production select one or several goods to carry out the wall thickness detection.This method is based on the sample examination method of probability theory, therefore, exists omission inevitably.The utility model carries out online detection to system of parison wall thickness, can realize 100% check to product quality.The wall thickness data of online detection can be used for control of product quality, with quality, the assurance uniformity in product performance of improving product.
(3) the utility model is simple to operate, realization is easy, cost is lower, can be conveniently used in existing blow moulding equipment is undergone technological transformation, and significantly improves the performance and the qualification rate of blow molded product.
Description of drawings
Fig. 1 is the structural representation of the utility model based on the extrusion-blow molding product wall thickness on-line control system of image recognition technology.
Fig. 2 is the master control program flow chart of the utility model method.
Fig. 3 is the frame picture that the utility model system of parison wall thickness on-line detecting system obtains.
Fig. 4 is the testing result of the utility model parison border and surface ink trace.
Fig. 5 is the schematic diagram of the fuzzy iterative learning control in the utility model method.
The specific embodiment
Below in conjunction with embodiment and accompanying drawing the utility model is described in further detail, but embodiment of the present utility model is not limited thereto.
Embodiment
Fig. 1 shows concrete structure of the present utility model.As seen from Figure 1, this extrusion-blow molding product wall thickness control system comprises head 1, servo valve 2, extruder 3, rotation-speed measuring device 4, Programmable Logic Controller host computer 5, Programmable Logic Controller slave computer 6, system of parison wall thickness control panel 7, RS232 communication card 8, display 9, video output card 10, RS232 serial port expanding module 11, industrial computer 12, image pick-up card 13, scriber 14, photoelectric sensor 15, video camera 16; Described video camera 16 is connected with image pick-up card 13 by cable, described image pick-up card 13 inserts on the mainboard of industrial computer 12 by pci bus, video output card 10 inserts on the mainboard of industrial computer 12 by the VGA bus, video output card 10 is connected with display 9, rotation-speed measuring device 4, scriber 14 and photoelectric sensor 15 be the COM1 by cable and RS232 serial port expanding module 11 respectively, COM2 is connected with COM3, Programmable Logic Controller host computer 5 and Programmable Logic Controller slave computer 6 are connected by cable, system of parison wall thickness control panel 7 is installed on the Programmable Logic Controller slave computer 6, servo valve 2 is connected with system of parison wall thickness control panel 7, and industrial computer 12 is connected with Programmable Logic Controller slave computer 6 by RS232 serial ports 12 and RS232 communication card 8.
This is as follows based on the extrusion-blow molding product wall thickness on-line control system each several part type selecting of image recognition technology: head 1 can be selected common convergence type head for use; Servo valve 2 can be selected the G631-3005A of Moog company for use; 5 liters of extrusion blow molding machines that extruder 3 can select for use Zhangjiagang Tongda Machinery Co., Ltd. to produce; Rotation-speed measuring device 4 is optional, and to hold up model that meter electronics Co., Ltd of section produces with Shanghai be the controller that multi-functional speed-frequency measuring instrument, Programmable Logic Controller host computer 5, Programmable Logic Controller slave computer 6, system of parison wall thickness control panel 7, the RS232 communication card 8 of MFT can be selected the 49N0-0G1AY-Y00-0-00 banding pattern base wall thickness control panel of Barber-Colman company for use; The 107P5 of the optional PHILIPS of display 9 company; The HD2600XT of video output card 10ATI Radeon; The JaRa 1104 that RS232 serial port expanding module 11 can select for use JaRa company to produce; Industrial computer 12 can be selected the AIMB-742 industrial computer of ADVANTECH company for use; The model that RT-300, the scriber 14 that image pick-up card 13 can select for use CREATIVE company to produce can select for use Boshan Xin Te electrical machinery plant to produce is the buncher of 61K180RA-AF and loads onto paintbrush; Photoelectric sensor 15 can be selected the E3X-MA11 of Omron for use; The HV-2616 that video camera 16 can select for use Unican to produce.By the described annexation of top specification connection is installed then, just can realizes this on-line control system preferably.
The operating procedure of utilizing the extrusion-blow molding product wall thickness On-Line Control Method that system shown in Figure 1 realizes specifically comprises as shown in Figure 2:
(1) to a blow-molded article that has particular wall thickness to require, according to its Thickness Distribution data, make final wall thickness meet the requirement of target wall thickness by debugging repeatedly, after acquisition meets the blow-molded article of target wall thickness requirement, start the online detection module of system of parison wall thickness, scriber begins to rule on parison according to certain time interval, rotation-speed measuring device begins to measure screw speed simultaneously, and rotating speed is transferred to industrial computer by the RS232 serial ports, when extruded parisons arrives the photoelectric sensor position, start the camera photography system, and give industrial computer (Fig. 3 is the frame picture that the system of parison wall thickness on-line detecting system obtains) with the image real-time Transmission by image pick-up card, analysis software passes through to number of pixels in the actual size of parison and the image relatively just can draw the proportionate relationship of actual size and pixel.Poor according to the pixel between adjacent two black traces, just can from testing result, calculate the distance of external diameter and each black trace of parison, (Fig. 4 is the testing result of parison border and surface ink trace), analysis software can obtain the weight of each black trace according to the frequency of the screw speed of real time record and scriber, can obtain the data such as Thickness Distribution of the internal diameter and the parison of parison according to mass conservation law.
(2) the head die gap curve with gained in the step (1) is input to the industry control processing module as initial value, and regulates the die gap control module by the industry control processing module, and the head die gap is controlled, and carries out blow molding operation.
(3) in the blowing process, the online detection module of system of parison wall thickness obtains the wall thickness data of extruded parisons automatically, and it is fed back to the industry control processing module.
(4) computer carries out analytic record according to input information to the wall thickness of goods, and calculate the departure of detected value and desired value, the product wall thickness curve of this departure and record is analyzed, and blur iterative learning control and calculate (idiographic flow is seen Fig. 5), the head die gap curve that must make new advances is controlled the blowing process, to realize the On-line Control of blowing process.The output of controlled quentity controlled variable is to link to each other with Programmable Logic Controller slave computer 6 by RS232 serial ports 11 and RS232 communication card 8, be transferred to system of parison wall thickness control panel 7 then, system of parison wall thickness control panel 7 is according to the data-driven servo valve 2 of input, thereby realize the control of die gap and carry out next time blow molding operation, so circulation meets the demands up to the product wall thickness that is obtained.
The foregoing description is the utility model preferred implementation; but embodiment of the present utility model is not restricted to the described embodiments; other any do not deviate from change, the modification done under spiritual essence of the present utility model and the principle, substitutes, combination, simplify; all should be the substitute mode of equivalence, be included within the protection domain of the present utility model.
Claims (6)
1, a kind of extrusion-blow molding product wall thickness on-line control system based on image recognition technology, it is characterized in that: comprise the online detection module of system of parison wall thickness, industry control processing module, die gap control module, the online detection module of described system of parison wall thickness is connected with the industry control processing module, and described industry control processing module is connected with the die gap control module.
2, the extrusion-blow molding product wall thickness on-line control system based on image recognition technology according to claim 1, it is characterized in that: the online detection module of described system of parison wall thickness comprises: rotation-speed measuring device, scriber, video camera, image pick-up card, photoelectric sensor, described video camera is connected with image pick-up card, and described image pick-up card, rotation-speed measuring device, scriber, photoelectric sensor are connected with the industry control processing module.
3, the extrusion-blow molding product wall thickness on-line control system based on image recognition technology according to claim 2, it is characterized in that: described video camera is installed in the below of extruder head, its camera lens and parison intermediate point are on same horizontal plane, and it is vertical with the head center line, with the distance of center line be 40～50cm, described video camera is connected with image pick-up card.
4, the extrusion-blow molding product wall thickness on-line control system based on image recognition technology according to claim 2, it is characterized in that: described scriber is installed in the position of the below 4～5cm of extruder head, and scriber is connected with industrial computer by the RS232 serial ports; Described rotation-speed measuring device is connected with industrial computer by the RS232 serial ports; Described photoelectric sensor and reflector are installed in the head below, and its light path intersects with the head center line and be vertical with it; Described photoelectric sensor is connected with industrial computer by the RS232 serial ports.
5, the extrusion-blow molding product wall thickness on-line control system based on image recognition technology according to claim 1, it is characterized in that: described industry control processing module comprises industrial computer, Programmable Logic Controller, output port, many serial port expanding modules, described Programmable Logic Controller is connected with industrial computer by output port, and described industrial computer is connected with external equipment by output port.
6, the extrusion-blow molding product wall thickness on-line control system based on image recognition technology according to claim 1, it is characterized in that: described die gap control module comprises system of parison wall thickness control panel, servo valve and hydraulic system, described system of parison wall thickness control panel is connected with servo valve, and described servo valve is connected with hydraulic system.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNU2008200448357U CN201179725Y (en) | 2008-03-13 | 2008-03-13 | Intelligentized control system for wall thickness of extrusion-blow molding product based on image recognition technique |
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| Application Number | Priority Date | Filing Date | Title |
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| CNU2008200448357U CN201179725Y (en) | 2008-03-13 | 2008-03-13 | Intelligentized control system for wall thickness of extrusion-blow molding product based on image recognition technique |
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| CF01 | Termination of patent right due to non-payment of annual fee |
Granted publication date: 20090114 Termination date: 20110313 |