摘要
混炼过程是橡胶加工中必不可少的重要环节。炭黑、白炭黑等填料作为橡胶制品重要的补强剂,其分散性的好坏直接影响到胶料的物理机械性能和后续加工性能,甚至橡胶产品的质量和使用寿命。炭黑等补强剂分散不均,易形成大的凝胶块,不仅不利于压延、挤出等后续加工工艺的顺利进行,对高速制品还容易引起动平衡问题。炭黑(包含白炭黑等补强剂)分散度主要反映的是炭黑等补强剂在胶料中的分散情况。它与混炼方法、混炼时间等多个因素有关,如上顶栓压力、转子转速、冷却水温度、转子结构和类型等条件的变化都会产生不同的混炼效果。研究炭黑在混炼过程中的分散机理,量化评定其分散程度有利于改善混炼工艺和橡胶制品的质量。
目前,可自动评价炭黑分散度的仪器虽然在橡胶工业中已经得到较为广泛的应用,但存在的问题也是非常明显的,具体表现在炭黑与橡胶之间没有明显的界限,炭黑的识别存在较大误差；分散度评价方法不够科学和完整,仅能在局部范围内评价炭黑的破碎程度,未能实现其整体破碎和扩散程度的评价；炭黑分散过程稳定性仅能通过反映密炼机瞬时功率的过程曲线间接的表征等等。
针对这些问题,本文对炭黑的识别、炭黑形态特征的表征、分散度评价体系的建立、炭黑分散过程稳定性的判断进行了深入地研究,具体工作如下：
1.结合对胶料图像特点的分析,通过对几种图像分割算法的比较,选择K均值法作为识别炭黑的方法。针对K均值法存在的问题,提出了两种优化方法：基于对称分布的优化方法和基于拐点的优化方法。通过对比实验结果,认为基于拐点的优化方法更加合理。运用K均值法,并结合基于拐点的图像优化方法,解决了区分炭黑和橡胶的问题。
2.针对炭黑结构形态对胶料性能产生的影响,提出了通过长径比、形态复杂度来表征炭黑形态特征的方法。椭圆拟合法和最小外接长方形法的运用,解决了长径比的计算问题。经实验数据对比,认为椭圆拟合法更加合理。基于凸包的方法和基于周长的方法解决了形态复杂度的表征问题。实验结果表明,基于周长的方法更准确。
3.通过观察对比,发现了炭黑与杂质形态上的差异性,实现了胶料图像中丝状杂质、划痕等的处理。针对丝状杂质成弧形、周长比较长等特点,通过计算区域中空面积和周长与实心率的比值来识别该类型杂质。实验数据表明,中空面积大于3个像素、或者周长与实心率的比值大于160的区域可以认为是该类型杂质。对于划痕等线型杂质,实验结果表明,长径比不小于6.5的区域可以认定为该类型杂质。
4.通过对标准图片的研究和分析,发现了“炭黑的总面积和个数随着分散度的提高不断变小”这一变化规律。本文以炭黑的总面积或个数为基础,并结合炭黑面积特征区间的划分,建立了四种评价炭黑微观分散度的模型。实验数据表明,基于面积的8特征区间的评价模型比较合理。
5.引入统计过程控制(SPC)方法,在对炭黑进行多点检测的基础上,通过分析炭黑浓度是否满足稳定状态下数据分布的要求,实现了炭黑分散过程稳定性的判断。再利用多点检测的炭黑数据,计算出可以反映炭黑宏观破碎程度和扩散程度的特征值(主要包括均值、偏度、峰度)。
本文在研究如何更准确的识别炭黑的基础上,实现了炭黑形态特征的量化表征,建立了一套从微观和宏观两个层面综合评价炭黑分散度的体系,提出了更直接评价炭黑分散稳定性的方法,并开发出一套与之相对应的软件系统。课题的研究成果,对研究混炼过程中各工艺参数变化对分散度的影响,建立分散度和胶料物理性能之间的对应关系,最终实现混炼过程的优化提供理论支持和实验依据。
Mixing is absolutely necessary and important in the process of rubber processing. The dispersion of rubber product's important reinforcing fillers, such as carton black and white carton black, has great influence on rubber's physical and mechanical properties and processing performance, even rubber product's quality and service life. It's easy to form big tiles when carton black's dispersion is uneven, which is not only bad to the subsequent process, such as rolling, extruder, but also causes unbalance problem of products with great speed. The dispersion of carton black(including other fillers) shows dispersing condition of carton black in rubber, which is related with many factors, such as convertible-top peg's press, rotor's speed, cooling water's temperature, rotor's structure and type. Changing these factors will have an effect on mixing. It's great meaningful for improving mixing process and quality of rubber product to research carton black's dispersion theory and evaluate carton black's dispersion.
At present, the devices that can evaluate carton black's dispersion automatically have been great application in rubber industry, but their problems are also obvious. for example, there are some deviations in recognizing carton black of rubber image because there is not obvious boundary between carton black and rubber. The method of evaluating dispersion is not enough complete and scientific, the result of evaluation just represents local carton black's fragmentation, not shows the degree of carton black's whole fragmentation and diffusion. The stability of carton black's dispersion process is just characterized by process curve which shows instantaneous power of mixer.
In accordance with these problems, this paper researched identifying carton black, characterizing carton black's morphology, building the dispersion evaluation system, judging the stability of carton black's dispersion process deeply, special works included:
1. By the way of comparing several typical image segmentation algorithm combined with analysis of rubber image's feature, k-means method was selected to process image. Thinking about the problems of k-means, two methods were supplied: the method based on symmetric distribution and the method based on inflection point. By comparing outcomes of experiments, the method based on inflection point was more reasonable. Combining the method based on inflection point, k-means algorithm solved the problem of distinguish carton black and rubber.
2. Given the influence of carton black's shape on rubber's property, A new method was supported that the parameters, such as length diameter ratio, morphology complexity, were used to characterize carton black's shape. The method of ellipse fitting and the method of minimum bounding rectangle solved the problem of calculating length diameter ratio. Experiments proved that the method of ellipse fitting was more reasonable. The method based on convex hull and the method based on perimeter solved the problem of calculating morphology complexity. Experiments proved that the method of perimeter was more precise.
3. According to the difference between impurity and carton black, filamentous impurities and scratches in rubber image was disposed. According to the characteristics of long perimeter and arc about filamentous impurities, the ratio of perimeter to solidity of region and hole's area were calculated to distinguish this type of impurity. Experiments proved that if hole's area was larger than3pixels or the value of the ratio larger than160, the region was regarded as filamentous impurity. For linear impurity, such as scratch, experiments proved that if a region's length-diameter ratio is larger than6.5, the region was regarded as scratch.
4. Though analyzing standard images, the rule was found that the whole area and count of carton black changed smaller with the improvement of dispersion level. Combined with divided feature regions, this paper built four evaluation models about carton black's microcosmic dispersion on the basis of the whole area and count of carton black. Experiments proved that the model had eight feature regions based on area was more reasonable.
5. According to the theory that product's feature values satisfied normal distribution in the stable process, on the basis of detecting carton black many times, SPC was used to judge whether canton black's density satisfied the requirement of data distribution in the stable process, which decided the stability of carton dispersing process. According to the detected data, the feature values (including mean, skewness, kurtosis) were calculated, which described macroscopic fragmentation and diffusion of carton black.
On the basis of identifying carton black more precisely, this paper built an evaluation model that represented the degree of fragmentation and diffusion from local and global perspectives,supplied a new method of evaluating carton black's dispersion stability directly and developed corresponding software system. The project researching was helpful for researching the influence of changing process parameters on carton black's dispersion, building the relationship between dispersion and rubber's physical properties, which was used to optimizing mixing process.
引文
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