Weighing method for high-performance aluminum alloy production
By using high-precision weighing sensors and high-definition cameras on the high-performance aluminum alloy production line, combined with the data processing center, high-precision and real-time weight monitoring and process optimization are achieved, solving the accuracy and stability problems of traditional weighing methods, and improving the quality and stability of the traditional weighing methods. Production efficiency and product quality.
Patent Information
- Application Number
- CN202410851098.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-28
- Publication Date
- 2024-12-27
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
In the production process of high-performance aluminum alloys, traditional weighing methods cannot achieve real-time online measurement, have low accuracy and are easily disturbed by production environment, cannot meet the strict requirements of high-performance aluminum alloys for quality and performance, and lack data integration and intelligence. Measurement monitoring function.
Using multiple high-precision weighing sensors combined with high-definition cameras, we collect weight and shape information of aluminum alloy materials in real time, and conduct real-time analysis and optimization through the data processing center to ensure the accuracy and stability of weighing data, and combine production line speed and Automatic adjustment of process parameters.
It realizes high-precision and real-time weight monitoring, improves the consistency of production efficiency and product quality, reduces waste rate and manual intervention, enhances market competitiveness, and provides detailed data recording and process optimization basis.
Smart Images
Figure CN119197734A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to a weighing method for producing high-performance aluminum alloys, in particular to an online weighing method for producing high-performance aluminum alloys. Background Art
[0002] With the rapid development of modern industry, the demand for high-performance aluminum alloys is growing. In the production process of aluminum alloys, accurate weight information is crucial for quality control, cost accounting, process optimization, etc. Traditional weighing methods often have many limitations, such as not being able to be performed online in real time, low measurement accuracy, and being easily disturbed by the production environment. In the production of high-performance aluminum alloys, due to its strict requirements on quality and performance, a more accurate, reliable and real-time feedback weighing method is required. The production of high-performance aluminum alloys usually adopts a continuous and automated production line, which requires the weighing system to be closely integrated with the production process to achieve accurate weighing without affecting production efficiency. The composition and process of high-performance aluminum alloys are complex and diverse, and the weight control standards for products of different batches and specifications are also different.
[0003] Therefore, an online weighing technology with strong adaptability, flexible adjustment and precise measurement is needed. At the same time, in order to better monitor the production process and ensure product quality, weighing data needs to be effectively integrated and analyzed with other production parameters. The weight accuracy requirements for aluminum alloy products are extremely high, which poses a severe challenge to online weighing methods. In addition, with the advancement of intelligent manufacturing, online weighing methods also need to have functions such as data transmission, remote monitoring and intelligent diagnosis to meet the needs of modern production management. In this technical context, the development of an efficient, accurate and intelligent online weighing method for high-performance aluminum alloy production has become an inevitable requirement and one of the key technologies for the development of the industry. Summary of the invention
[0004] In order to solve the technical problems raised by the above background technology, the present invention is proposed. An embodiment of the present invention provides an online weighing method for high-performance aluminum alloy production.
[0005] The purpose of the present invention can be achieved by the following technical solution: an online weighing method for high-performance aluminum alloy production, the specific steps are as follows:
[0006] Collect aluminum alloy weighing data: Set up multiple high-precision weighing sensors on each type of aluminum alloy production line, evenly distributed on the conveyor track. Specifically, use a laser rangefinder to measure the length of each type of aluminum alloy production line to obtain the length of each type of aluminum alloy production line, obtain the production speed of aluminum alloy production from the database, set a desired measurement density, and obtain the length of the aluminum alloy production line divided by the set measurement density to get the required number of weighing sensors. When installing the weighing sensor, ensure that it is firmly connected to the conveyor track to avoid vibration or displacement factors affecting the measurement accuracy. Various types of aluminum alloy materials are identified by high-definition cameras. When the equipment receives an operating signal and starts the operating state of the equipment, the equipment automatically uploads the aluminum alloy raw materials to the conveyor belt of the production line. The high-definition camera identifies the shape of various types of aluminum alloy raw materials, including identifying various types of raw materials as granular, regular objects and irregular objects, thereby obtaining the apparent image of each type of raw material, and then the apparent damaged area and damaged quantity of each type of raw material are collected through the apparent image to obtain the damaged area parameter s and damaged quantity parameter p of each type of raw material. The apparent image of each type of raw material is specified in the extraction database, and the actual apparent image of each type of raw material is matched with the specified apparent image of each type of raw material to obtain the overlapping contour of each type of raw material, and the overlapping area parameter w of each type of raw material is obtained.
[0007] Analyze the transmission speed of the production line: Analyze the transmission speed of the aluminum alloy production line, transport various types of aluminum alloy raw materials through the conveyor belt, record the transmission time of various types of aluminum alloy materials through high-definition cameras, obtain the transmission time parameter T of various types of aluminum alloy materials, and measure the displacement distance of various types of aluminum alloy raw materials to obtain the transmission distance parameter F of various types of aluminum alloys within a fixed time. Divide the transmission displacement parameter of each type of aluminum alloy within a fixed time by the fixed time parameter of aluminum alloy transmission to obtain the transmission speed parameter G1 of the aluminum alloy. Similarly, obtain the actual transmission speed parameter G2 of the conveyor belt. Extract the standard transmission speed parameter range of the aluminum alloy production line in the database, and compare the actual transmission speed parameter obtained with the standard transmission speed parameter range. If the actual transmission speed parameter is greater than or less than the standard transmission speed parameter, it means that it is unqualified. On the contrary, it means that the speed is within the standard range.
[0008] By setting different transmission speeds, we compared whether there was any influence on the weighing measurement of the same aluminum alloy at the corresponding three speeds. We collected the weighing weight of the aluminum alloy material ɑ at high speed and recorded the data to obtain the weighing weight β. We collected the weighing weight of the aluminum alloy material α at medium speed to obtain the weighing weight ɡ. We collected the weighing weight of the aluminum alloy material ɑ at low speed to obtain the weighing weight μ. We calculated the average value of the three weighing weights to obtain the average weight EP. Then, we calculated the weight of the aluminum alloy material α at low speed to obtain the weighing weight μ. Get the fluctuation value s of the weighing weight 2 The influence of the speed on the weighing of aluminum alloy during the transmission process is compared by obtaining the fluctuation value and the weighing average value. If the difference between the fluctuation value and the average value is small, it means that the transmission speed has little influence on the weighing data and the data stability is good; if the fluctuation of the measured data is greatly different at different transmission speeds, it means that the transmission speed has a greater influence on the data and the data stability is poor.
[0009] Analysis of aluminum alloy weight data: When various types of aluminum alloy materials pass through the production line, the weighing sensor collects weight data in real time and transmits the data to the data processing center. Advanced data transmission technology is used to ensure that the data transmission between the weighing sensor and the data processing center is real-time and stable. Specifically: according to the length and transmission speed of the production line, different weighing sensors are installed. When various types of aluminum alloy materials enter the weighing range of the first weighing sensor, the weighing weight of each type of aluminum alloy material is measured, the first weighing weight of the aluminum alloy is obtained, and a signal is sent to the signal receiving end of the third sensor. When various types of aluminum alloy materials enter the measuring range of the second sensor, the first weighing weight of each type of aluminum alloy is monitored to confirm whether it is accurate, the second weighing weight is obtained, and a signal is sent to the signal end of the third sensor. When the aluminum alloy enters the measuring range of the third sensor, each type of aluminum alloy is weighed and the first weighing weight, second weighing weight and third weighing weight obtained are sent to the processing terminal. Each type of aluminum alloy material processes and classifies the results obtained by the processing terminal.
[0010] Data processing center: Real-time analysis and processing of received weight data. The three weighing weights obtained by the weighing sensor are compared with the first weighing weight and the second weighing weight. If the second weighing weight is greater than or less than the first weighing weight, it means that the weighing weights of each type are not standard. If the second weighing weight is equal to the first weighing weight, it means that the sensor weighing is standard. Similarly, the third weighing weight is compared with the first two to obtain a weighing comparison. The processing terminal identifies the weighing weight comparison result and sends an execution result signal to the production line equipment terminal for the aluminum alloy materials with the same weighing weight. The production line equipment terminal processes the corresponding aluminum alloy materials. If the three weighing weight results are different, the processing terminal sends a signal to the production line equipment terminal, the equipment terminal removes the corresponding aluminum alloy materials, and sends the execution signal to the mobile phone terminal of the monitoring personnel with the shortest distance. The monitoring personnel receive the signal and perform fault identification on the aluminum alloy materials and equipment respectively.
[0011] Data adjustment and optimization: Real-time adjustment and optimization of the production process based on the weighing data. When abnormal weight data is found, in combination with other production parameters and data, in-depth analysis of the cause of the abnormality is carried out. When the weighing data of the weighing sensor continuously appears incorrect, the equipment terminal suspends the movement of the aluminum alloy production line, obtains the signal of the mobile terminal of the nearest maintenance personnel, sends a compensation signal to the mobile terminal of the maintenance personnel, and the maintenance personnel receives the signal and repairs the corresponding equipment. When it is found that the processing temperature is deviated, the relevant parameters in the production process are adjusted in time according to the analysis results to optimize the processing temperature and time. By adjusting and optimizing the production process in real time, it is ensured that the weight of aluminum alloy products is always kept within the standard range, and the product quality and consistency are improved.
[0012] Compared with the prior art, the invention has the following beneficial effects: real-time quality monitoring can timely find out whether the product weight meets the standard, so as to quickly take adjustment measures to ensure the consistency and stability of product quality. Improving production efficiency avoids the cumbersome process and time delay of offline weighing, making the production process smoother and more efficient. Optimizing process control According to the real-time weighing data feedback, the production process parameters can be accurately adjusted to further improve the performance and quality of aluminum alloys. Reducing the scrap rate By timely discovering weight anomalies and correcting them, the scrap generation caused by weight problems is reduced, and costs are saved. Data traceability provides detailed weight data records for the production process, which is convenient for quality tracing and problem analysis. Improving the level of automation helps to achieve a high degree of automation in production, reduce manual intervention, and reduce human errors. Enhancing market competitiveness Stable and reliable quality and efficient production methods are conducive to improving the competitiveness of enterprises in the market. Rational use of resources Accurately grasp product weight information helps to reasonably arrange the use of raw materials and inventory management. Promoting process improvement The long-term accumulated weighing data can provide a strong basis for process innovation and optimization. BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. The following drawings are not intentionally scaled to the actual size, and the focus is on illustrating the main purpose of the present invention.
[0014] Figure 1 The figure is a flow chart of the method of the present invention. DETAILED DESCRIPTION
[0015] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work also fall within the scope of protection of the present invention.
[0016] See also Figure 1 As shown, the present invention is an online weighing method for high-performance aluminum alloy production, comprising the following steps:
[0017] Step 1. Collect aluminum alloy weighing data: Set up multiple high-precision weighing sensors on each type of aluminum alloy production line, evenly distributed on the conveyor track. Specifically, use a laser rangefinder to measure the length of each type of aluminum alloy production line to obtain the length of each type of aluminum alloy production line, obtain the production speed of aluminum alloy production from the database, set a desired measurement density, and obtain the length of the aluminum alloy production line divided by the set measurement density to get the required number of weighing sensors. When installing the weighing sensor, ensure that it is firmly connected to the conveyor track to avoid vibration or displacement factors affecting the measurement accuracy. Various types of aluminum alloy materials are identified by high-definition cameras. When the equipment receives an operating signal and starts the operating state of the equipment, the equipment automatically uploads the aluminum alloy raw materials to the conveyor belt of the production line. The high-definition camera identifies the shape of various types of aluminum alloy raw materials, including identifying various types of raw materials as granular, regular objects and irregular objects, thereby obtaining the apparent image of each type of raw material, and then the apparent damaged area and damaged quantity of each type of raw material are collected through the apparent image to obtain the damaged area parameter s and damaged quantity parameter p of each type of raw material. The apparent image of each type of raw material is specified in the extraction database, and the actual apparent image of each type of raw material is matched with the specified apparent image of each type of raw material to obtain the overlapping contour of each type of raw material, and the overlapping area parameter w of each type of raw material is obtained.
[0018] Step 2: Analyze the transmission speed of the aluminum alloy production line, transport various types of aluminum alloy raw materials through the conveyor belt, record the transmission time of various types of aluminum alloy materials through high-definition cameras, obtain the transmission time parameter T of various types of aluminum alloy materials, and measure the displacement distance of various types of aluminum alloy raw materials to obtain the transmission distance parameter F of various types of aluminum alloys within a fixed time. Divide the transmission displacement parameter of each type of aluminum alloy within a fixed time by the fixed time parameter of aluminum alloy transmission to obtain the transmission speed parameter G1 of the aluminum alloy, and similarly obtain the actual transmission speed parameter G2 of the conveyor belt. Extract the standard transmission speed parameter range of the aluminum alloy production line in the database, and compare the actual transmission speed parameter obtained with the standard transmission speed parameter range. If the actual transmission speed parameter is greater than or less than the standard transmission speed parameter, it means that it is unqualified. On the contrary, it means that the speed is within the standard range.
[0019] By setting different transmission speeds, we compared whether there was any influence on the weighing measurement of the same aluminum alloy at the corresponding three speeds. We collected the weighing weight of the aluminum alloy material ɑ at high speed and recorded the data to obtain the weighing weight β. We collected the weighing weight of the aluminum alloy material α at medium speed to obtain the weighing weight ɡ. We collected the weighing weight of the aluminum alloy material ɑ at low speed to obtain the weighing weight μ. We calculated the average value of the three weighing weights to obtain the average weight EP. Then we calculated Get the fluctuation value s of the weighing weight 2 The influence of the speed on the weighing of aluminum alloy during the transmission process is compared by obtaining the fluctuation value and the weighing average value. If the difference between the fluctuation value and the average value is small, it means that the transmission speed has little influence on the weighing data and the data stability is good; if the fluctuation of the measured data is greatly different at different transmission speeds, it means that the transmission speed has a greater influence on the data and the data stability is poor.
[0020] Step 3: When various types of aluminum alloy materials pass through the production line, the weighing sensor collects weight data in real time and transmits the weight data to the data processing center. Advanced data transmission technology is used to ensure that the data transmission between the weighing sensor and the data processing center is real-time and stable. Specifically, different weighing sensors are installed according to the length and transmission speed of the production line. When various types of aluminum alloy materials enter the weighing range of the first weighing sensor, the weighing weight of each type of aluminum alloy material is measured, the first weighing weight of the aluminum alloy is obtained, and a signal is sent to the signal receiving end of the third sensor. When various types of aluminum alloy materials enter the measuring range of the second sensor, the first weighing weight of each type of aluminum alloy is monitored to confirm whether it is accurate, the second weighing weight is obtained, and a signal is sent to the signal end of the third sensor. When the aluminum alloy enters the measuring range of the third sensor, each type of aluminum alloy is weighed and the first weighing weight, the second weighing weight and the third weighing weight obtained are sent to the processing terminal. Each type of aluminum alloy material processes and classifies the results obtained by the processing terminal.
[0021] Step 4: The data processing center performs real-time analysis and processing on the received weight data. The three weighing weights obtained by the weighing sensor are compared with the first weighing weight and the second weighing weight. If the second weighing weight is greater than or less than the first weighing weight, it means that the weighing weights of each type are not standard. If the second weighing weight is equal to the first weighing weight, it means that the sensor weighing standard is obtained. Similarly, the third weighing weight is compared with the first two to obtain a weighing comparison. The processing terminal identifies the weighing weight comparison result and sends an execution result signal to the production line equipment terminal for the aluminum alloy materials with the same weighing weight. The production line equipment terminal processes the corresponding aluminum alloy materials. If the three weighing weight results are different, the processing terminal sends a signal to the production line equipment terminal, the equipment terminal removes the corresponding aluminum alloy materials, and sends the execution signal to the mobile phone terminal of the monitoring personnel with the shortest distance. The monitoring personnel receives the signal and identifies the aluminum alloy materials.
[0022] Step 5: Adjust and optimize the production process in real time based on the weighing data. When the weight data is abnormal, combine it with other production parameters and data to deeply analyze the cause of the abnormality. When the weighing data of the weighing sensor is incorrect, the equipment terminal will suspend the movement of the aluminum alloy production line, obtain the signal of the mobile terminal of the nearest maintenance personnel, send a compensation signal to the mobile terminal of the maintenance personnel, and the maintenance personnel will repair the corresponding equipment after receiving the signal. If it is found that the processing temperature is deviated, adjust the relevant parameters in the production process in time according to the analysis results, and optimize the processing temperature and time. By adjusting and optimizing the production process in real time, ensure that the weight of aluminum alloy products is always kept within the standard range, and improve product quality and consistency.
[0023] The above is an explanation of the present invention and should not be considered as a limitation thereof. Although several exemplary embodiments of the present invention have been described, it will be readily appreciated by those skilled in the art that many modifications may be made to the exemplary embodiments without departing from the novel teachings and advantages of the present invention. Therefore, all such modifications are intended to be included within the scope of the present invention as defined in the claims. It should be understood that the above is an explanation of the present invention and should not be considered as being limited to the specific embodiments disclosed, and modifications to the disclosed embodiments and other embodiments are intended to be included within the scope of the appended claims. The present invention is defined by the claims and their equivalents.
Claims
1. A weighing method for high performance aluminum alloy production, characterized in that: The steps include: Step 1: Collect aluminum alloy weighing data; Step 2, analyzing the transmission speed of the aluminum alloy production line; specifically: transporting various types of aluminum alloy raw materials through a conveyor belt, recording the transmission time of various types of aluminum alloy materials through a high-definition camera, obtaining the transmission time parameter T of each type of aluminum alloy material, and measuring the displacement distance of each type of aluminum alloy raw material to obtain the transmission distance parameter F of each type of aluminum alloy within a fixed time, dividing the transmission displacement parameter of each type of aluminum alloy within a fixed time by the aluminum alloy transmission fixed time parameter to obtain the aluminum alloy transmission speed parameter G1, and similarly obtaining the actual transmission speed parameter G2 of the conveyor belt; extracting the standard transmission speed parameter interval of the aluminum alloy production line from the database, and converting the obtained actual transmission speed parameter F into a fixed time parameter. The actual transmission speed parameter is compared with the standard transmission speed parameter range. If the actual transmission speed parameter is greater than or less than the standard transmission speed parameter, it means that it is unqualified. On the contrary, it means that the speed is within the standard range. By setting different transmission speeds, compare whether there is any influence on the weighing measurement of the same aluminum alloy at the corresponding three speeds. Collect the weighing weight of the aluminum alloy material ɑ at high speed and record the data to obtain the weighing weight β. Collect the weighing weight of the aluminum alloy material α at medium speed to obtain the weighing weight ɡ. Then collect the weighing weight of the aluminum alloy material ɑ at low speed to obtain the weighing weight μ. Calculate the average value of the three weighing weights to obtain the average weight EP, and then calculate the fluctuation value of the weighing weight. Step 3: When various types of aluminum alloy materials pass through the production line, the weighing sensor collects weight data in real time and transmits the data to the data processing center; Step 4: The data processing center performs real-time analysis and processing on the received weight data; Step 5: Adjust and optimize the production process in real time based on the weighing data.
2. A weighing method for high performance aluminum alloy production according to claim 1, characterized in that: The specific steps for collecting aluminum alloy weighing data in step 1 are as follows: The length of each type of aluminum alloy production line is measured by a laser rangefinder to obtain the length of each type of aluminum alloy production line, the production speed of aluminum alloy production is obtained from the database, an expected measurement density is set, and the length of the aluminum alloy production line is obtained by dividing the set measurement density to obtain the required number of weighing sensors; each type of aluminum alloy material is identified by a high-definition camera. When the equipment receives an operation signal and starts the operation state of the equipment, the equipment automatically uploads the aluminum alloy raw materials to the conveyor belt of the production line. The high-definition camera identifies the shape of each type of aluminum alloy raw material, including identifying each type of raw material as granular, regular objects and irregular objects, thereby obtaining the apparent image of each type of raw material, and then the apparent damage area and damage quantity of each type of raw material are collected through the apparent image to obtain the damage area parameter s and damage quantity parameter p of each type of raw material, and the apparent image of each type of raw material is specified in the database, and the actual apparent image of each type of raw material is matched with the specified apparent image of each type of raw material to obtain the overlap contour of each type of raw material, and the overlap area parameter w of each type of raw material is obtained.
3. A weighing method for high performance aluminum alloy production according to claim 1, characterized in that: The specific steps for the weighing sensor to collect weight data in real time in step 3 are as follows: A number of weighing sensors are installed according to the length and transmission speed of the production line. When each type of aluminum alloy material enters the weighing range of the first weighing sensor, the weighing weight of each type of aluminum alloy material is measured, the first weighing weight of the aluminum alloy is obtained, and a signal is sent to the signal receiving end of the third sensor. When each type of aluminum alloy material enters the measuring range of the second sensor, the first weighing weight of each type of aluminum alloy is monitored to confirm whether it is accurate, the second weighing weight is obtained, and a signal is sent to the signal end of the third sensor. When the aluminum alloy enters the measuring range of the third sensor, each type of aluminum alloy is weighed and the obtained first weighing weight, second weighing weight and third weighing weight are sent to the processing terminal. Each type of aluminum alloy material processes and classifies the results obtained by the processing terminal.
4. A weighing method for high performance aluminum alloy production according to claim 1, characterized in that: The specific steps for real-time analysis and processing of the received weight data in step 4 are as follows: The three weighing weights obtained by the weighing sensor are compared with the first weighing weight and the second weighing weight. If the second weighing weight is greater than or less than the first weighing weight, it means that the weighing weights of each type are not standard. If the second weighing weight is equal to the first weighing weight, it means that the sensor weighing is standard. Similarly, the third weighing weight is compared with the first two to obtain a weighing comparison. The processing terminal identifies the weighing weight comparison result and sends an execution result signal to the production line equipment terminal for the aluminum alloy materials with the same weighing weight. The production line equipment terminal processes the corresponding aluminum alloy materials. If the three weighing weight results are different, the processing terminal sends a signal to the production line equipment terminal, the equipment terminal removes the corresponding aluminum alloy materials, and sends the execution signal to the mobile phone terminal of the monitoring personnel with the shortest distance. The monitoring personnel receive the signal and perform fault identification on the aluminum alloy materials and equipment respectively.
5. A weighing method for high performance aluminum alloy production according to claim 1, characterized in that: The specific steps for real-time adjustment and optimization of the production process according to the weighing data in step 5 are as follows: When the weighing data of the weighing sensor continuously appears to be incorrect, the equipment terminal suspends the movement of the aluminum alloy production line, obtains the signal of the nearest maintenance personnel's mobile terminal, and sends a compensation signal to the maintenance personnel's mobile terminal. The maintenance personnel receives the signal and repairs the corresponding equipment. If it is found that there is a deviation in the processing temperature, the relevant parameters in the production process are adjusted in time according to the analysis results to optimize the processing temperature and time.