Continuous rack plating method for vehicle hardware

Abstract

The invention relates to the technical field of metal surface treatment, and discloses a vehicle hardware continuous rack plating method which comprises the following steps: production line layout optimization: according to the size, the shape and the production requirements of a workpiece, a computer simulation and dynamic adjustment technology is adopted, the production line layout is optimized, the workshop space utilization rate is optimized, and a production environment is provided for the continuous rack plating process; ultrasonic-assisted electro-deposition is carried out, wherein the uniformity and compactness of a plating layer are improved; green energy management: supporting the operation of an electro-deposition process; a composite surface modification technology: improving the wear resistance and the surface performance of the workpiece; and intelligent monitoring and operation maintenance: identifying potential faults and carrying out early warning. The production line layout is optimized by adopting computer simulation and dynamic adjustment technologies, the workshop operation state is monitored and optimized in real time in combination with a digital twinning technology, the space utilization rate is increased, invalid movement is reduced, the production line flexibility is enhanced, and the requirements for diversified workpiece sizes and shapes are met.

Description

Technical Field

[0001] The invention relates to the technical field of metal surface treatment, in particular to a continuous rack plating method for vehicle hardware. Background Art

[0002] At present, metal surface treatment technology has developed into a relatively mature system, playing a vital role in the fields of automobile manufacturing, aerospace, etc. However, traditional metal surface treatment methods, such as electroplating and spraying, still have problems such as low efficiency, serious waste of resources and environmental pollution. Especially in the batch processing of automotive hardware, how to improve production efficiency and reduce costs while ensuring product quality has become an urgent issue to be solved in the industry.

[0003] The main problems faced by existing technologies: Although the existing continuous hanging plating technology has improved the automation level of hardware surface treatment to a certain extent, the space utilization efficiency is low due to the fixed equipment layout. In addition, the quality of the coating is greatly affected by manual operation, making it difficult to ensure that the coating is uniform and dense, which in turn affects the corrosion resistance and appearance of the product.

[0004] Existing solutions and their limitations: There are existing improvement measures that attempt to improve the quality of the coating by optimizing the design of the production line and enhancing the stability of the plating solution. However, these methods are less flexible when facing workpieces of different sizes and specifications, and it is difficult to flexibly adapt to the actual changes in demand on the production line. In addition, high energy consumption has always been one of the bottlenecks restricting the sustainable development of the metal surface treatment industry.

[0005] Challenges and opportunities: With the popularization of green and low-carbon concepts and the rapid development of new energy technologies, the development of energy-saving and environmentally friendly surface treatment technologies has become a new market trend. The combination of intelligent control systems and clean energy not only helps to save energy and reduce emissions, but also brings economic benefits to enterprises. Summary of the invention

[0006] In view of the shortcomings of the prior art, the present invention provides a method for continuous hanging plating of automotive hardware, which solves the problems of low space utilization caused by the fixed layout of existing equipment, significant influence of manual operation on the plating quality, poor adaptability to workpieces of different sizes and specifications, and high energy consumption limiting sustainable development.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: a method for continuous rack plating of automotive hardware, comprising: Production line layout optimization: According to the size, shape and production requirements of the workpiece, computer simulation and dynamic adjustment technology are used to optimize the production line layout, optimize the utilization of workshop space, and provide a production environment for the continuous rack plating process; Ultrasonic assisted electrodeposition: Based on the optimization of production line layout, ultrasonic assisted electrodeposition technology is used to improve the uniformity and density of the coating by controlling the current density distribution in the electrodeposition tank; Green energy management: Based on the energy demand of the production line, a comprehensive energy management system is established, combining the solar photovoltaic power generation system and the energy storage device. Through energy distribution, the daytime stored energy and the night-time low-peak electricity are coordinated to support the operation of the electrodeposition process; Composite surface modification technology: In the before and after stages of the rack plating process, ion implantation technology is used for surface pretreatment according to the properties of the workpiece, and laser cladding technology is used to strengthen the bonding strength of the coating, thereby improving the wear resistance and surface performance of the workpiece; Intelligent monitoring and operation and maintenance: Based on the Internet of Things monitoring system, equipment operation data is collected in real time during the production process. Through the remote operation and maintenance platform combined with big data analysis and fault prediction technology, the production process is dynamically optimized, potential faults are identified and early warnings are issued.

[0008] Preferably, the production line layout optimization comprises the following steps: Model the workpiece size and production batch through simulation software, and analyze and optimize the workpiece arrangement; Use the prediction model to predict the trend of workpiece size changes and dynamically adjust the production line layout based on the prediction results; Build a production line model based on digital twin technology, monitor the operating status of the workshop, and optimize the production line layout based on the monitoring results.

[0009] Preferably, an ultrasonic auxiliary device is provided in the electrodeposition tank, and the distribution of current density during the electrodeposition process is optimized by adjusting the frequency and power parameters of the ultrasonic wave, so as to improve the uniformity and density of the coating.

[0010] Preferably, the ultrasonic auxiliary device reduces the bubble aggregation generated during the electrodeposition process by adjusting the frequency and power parameters to improve the adhesion and uniformity of the coating.

[0011] Preferably, the green energy management includes: Power supply using solar photovoltaic power generation system and off-peak power of the grid; Storing excess solar power through energy storage devices and releasing it to meet production needs during peak electricity consumption; The energy dispatching system can optimize the allocation of electricity usage time and reduce energy consumption.

[0012] Preferably, the energy storage device regulates the use of stored energy through a dynamic charge and discharge management system to reduce dependence on an external power source.

[0013] Preferably, the composite surface modification technology includes: Enhance the bonding strength and wear resistance of the workpiece through surface modification before rack plating; After rack plating, the density and corrosion resistance of the coating are improved through strengthening treatment.

[0014] Preferably, the surface modification treatment is an ion implantation process, and the strengthening treatment is a laser cladding process.

[0015] Preferably, the intelligent monitoring and operation and maintenance includes a monitoring system based on the Internet of Things, which collects temperature, vibration and power data of the equipment in real time by installing sensors, and transmits the data to the operation and maintenance platform for analysis.

[0016] Preferably, the remote operation and maintenance platform provides early warning of potential equipment failures based on equipment operation data in combination with a fault prediction model.

[0017] The present invention provides a method for continuous rack plating of automotive hardware. It has the following beneficial effects: 1. The present invention optimizes the layout of the production line by adopting computer simulation and dynamic adjustment technology, and combines digital twin technology to monitor and optimize the operation status of the workshop in real time, thereby effectively improving the utilization rate of the workshop space, reducing the ineffective movement in the workpiece transmission, and improving the flexibility and efficiency of the production line, and adapting to the diverse workpiece size and shape requirements.

[0018] 2. The present invention effectively optimizes the current density distribution and solves the problem of uneven coating thickness by introducing an ultrasonic auxiliary device into the electrodeposition tank. At the same time, the vibration and cavitation effect of the ultrasonic wave can inhibit the aggregation of bubbles and significantly improve the adhesion and compactness of the coating, thereby improving the corrosion resistance and decorative effect of the coating.

[0019] 3. The present invention constructs a green energy management system, comprehensively utilizes solar photovoltaic power generation, energy storage devices and grid off-peak power, coordinates energy distribution during the day and at night, and dynamically adjusts the charging and discharging of energy storage devices, thereby achieving efficient energy utilization and reduced operating costs, reducing dependence on external power sources, and achieving the dual goals of green environmental protection and economic savings.

[0020] 4. The present invention enhances the bonding force and wear resistance of the workpiece surface through the ion implantation process before rack plating, and further improves the density and corrosion resistance of the coating through the laser cladding process after rack plating, significantly improving the surface performance of the workpiece. In addition, the intelligent monitoring and operation and maintenance system based on the Internet of Things can collect equipment operation data in real time, and identify potential equipment failures in advance in combination with the fault prediction model, thereby reducing unplanned downtime and ensuring the long-term stable operation of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 The figure is a flow chart of the method of the present invention. DETAILED DESCRIPTION

[0022] The following will be combined with the drawings in the specification of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0023] In order to better understand the present invention, the above contents are described in detail below in conjunction with specific embodiments. Please see attached Figure 1 The embodiment of the present invention provides a method for continuous rack plating of automotive hardware, comprising: Production line layout optimization: According to the size, shape and production requirements of the workpiece, computer simulation and dynamic adjustment technology are used to optimize the production line layout, optimize the utilization of workshop space, and provide a production environment for the continuous rack plating process; In this embodiment, the arrangement of the workpieces is modeled and optimized through simulation software according to the size, shape and production requirements of the workpieces, and the production line layout is adjusted in real time using computer simulation and dynamic adjustment technology to optimize the utilization of workshop space and reduce the ineffective movement distance of the workpieces in the production process. The layout of the production line modules is automatically adjusted according to the size changes of different batches of workpieces, providing an efficient and flexible production environment for the continuous plating process.

[0024] Ultrasonic assisted electrodeposition: Based on the optimization of production line layout, ultrasonic assisted electrodeposition technology is used to improve the uniformity and density of the coating by controlling the current density distribution in the electrodeposition tank; In this embodiment, ultrasonic-assisted electrodeposition technology is adopted on the basis of optimizing the production line layout, an ultrasonic auxiliary device is set in the electrodeposition tank, and the frequency, power and action time of the ultrasonic wave are adjusted to optimize the distribution of current density, reduce the bubble aggregation phenomenon generated during the electrodeposition process, and promote the uniform deposition of coating particles, thereby improving the uniformity and density of the coating, and enhancing the adhesion and corrosion resistance of the coating.

[0025] Green energy management: Based on the energy demand of the production line, a comprehensive energy management system is established, combining the solar photovoltaic power generation system and energy storage device. Through energy distribution, the daytime stored energy and the night-time off-peak power are coordinated to support the operation of the electrodeposition process; In this embodiment, a comprehensive energy management system is established according to the energy demand of the production line. The solar photovoltaic power generation system, energy storage device and off-peak power of the power grid are combined to optimize energy distribution through an intelligent energy dispatching system. The clean energy generated and stored by the solar photovoltaic system during the day and the low-cost electricity resources during the off-peak period at night are coordinated to ensure the continuous and stable operation of the electrodeposition process, while reducing overall energy consumption and production costs and improving energy utilization efficiency.

[0026] Composite surface modification technology: In the stages before and after the rack plating process, ion implantation technology is used for surface pretreatment according to the properties of the workpiece, and laser cladding technology is used to strengthen the bonding force of the coating, thereby improving the wear resistance and surface performance of the workpiece; In this embodiment, ion implantation technology is used for surface pretreatment and laser cladding technology is used for strengthening the coating in the front and back stages of the rack plating process. Ion implantation technology bombards the workpiece surface with high-energy ions to form a dense surface modification layer, thereby improving the bonding force and corrosion resistance of the coating; laser cladding technology uses a high-energy laser beam to form a uniform and dense cladding layer on the workpiece surface, further enhancing the mechanical strength and wear resistance of the coating, thereby significantly improving the overall surface performance and service life of the workpiece.

[0027] Intelligent monitoring and operation and maintenance: Based on the Internet of Things monitoring system, equipment operation data is collected in real time during the production process. Through the remote operation and maintenance platform combined with big data analysis and fault prediction technology, the production process is dynamically optimized, potential faults are identified and early warnings are issued.

[0028] In this embodiment, by installing sensors on the production line equipment during the production process, the operation data of the equipment, including temperature, vibration, power and other key parameters, is collected in real time, and the collected data is transmitted to the remote operation and maintenance platform. The operation and maintenance platform combines big data analysis and machine learning algorithms to dynamically evaluate the operation status of the equipment, identify abnormal modes and potential failure risks of the equipment, generate a failure prediction model, issue early warning signals in advance, guide the formulation of maintenance plans, and dynamically optimize the production process, reduce unplanned downtime, and improve the stability and operation efficiency of the production line.

[0029] Production line layout optimization includes the following steps: Model the workpiece size and production batch through simulation software, and analyze and optimize the workpiece arrangement; Use the prediction model to predict the trend of workpiece size changes and dynamically adjust the production line layout based on the prediction results; Build a production line model based on digital twin technology, monitor the operating status of the workshop, and optimize the production line layout based on the monitoring results.

[0030] In this embodiment, the production line layout optimization is achieved by the following steps: Step 1: Use simulation software to model the workpiece size and production batch, and analyze and optimize the workpiece arrangement.

[0031] Specifically, the geometric size, shape and batch requirements of the workpiece are used as input parameters to generate a two-dimensional layout model of the production workshop through simulation software. Each workpiece is defined as a rectangle or other geometric shape, with width and height represented by w respectively. i and h i , the workshop space is represented by a two-dimensional plane, whose area is A. The optimization goal is to minimize the total space waste of workpiece arrangement. The optimization formula is as follows: Where minimize L represents the total space waste, and N is the total number of artifacts; As an option, the modeling process can also consider the necessary spacing between workpieces to avoid collision interference during the transmission process. For example, if the minimum spacing between workpieces is set to d, the optimization formula is adjusted to: It should be noted that the modeling process can be applied to workpieces of different shapes, such as round and special-shaped parts, and different geometric expressions can be used for layout optimization analysis.

[0032] Step 2: Use the prediction model to predict the trend of workpiece size changes and dynamically adjust the production line layout based on the prediction results.

[0033] In some embodiments, considering that the workpiece size and batch size may fluctuate with the change of order demand, the present invention proposes to use a time series prediction model to predict the workpiece characteristics. Specifically, a long short-term memory network (LSTM) can be used to analyze historical workpiece data to predict the size change trend in the future.

[0034] The input of the prediction model is the historical workpiece size and production batch data output: X t =[x1,x2,…,x t ], which is the size and batch prediction value at the future time The prediction formula is as follows: Where F is the prediction model and W is the model parameter. For example, the prediction results can be used to adjust the layout of the production line in advance to adapt to changes in future production needs. As an option, the prediction model can be implemented in combination with regression analysis, support vector machine (SVM) and other methods in machine learning algorithms. The specific choice is determined by data characteristics and computational complexity.

[0035] Step 3: Build a production line model based on digital twin technology, monitor the operation status of the workshop, and optimize the production line layout based on the monitoring results.

[0036] Specifically, digital twin technology enables comprehensive monitoring of the production line's operating status by mapping the physical state of the production line into a virtual model in real time. A variety of sensors are installed at each key node of the production line (such as workpiece transmission equipment and plating area) to collect operating data, including equipment location, transmission speed, occupied space, etc.

[0037] These data are transmitted to the digital twin platform in real time through the IoT system to form a digital mapping model of the production line. Assuming that the state data collected by the sensor is D(t) = [p(t), v(t), s(t)], which represent the position, speed and space occupancy of the equipment respectively, the state update formula in the virtual model is as follows: M(t+1)=M(t)+ΔD(t) Among them, M(t) is the virtual model state at the current moment, ΔD(t) is the increment of the device state, and M(t+1) is the predicted virtual model state at the next moment.

[0038] In one possible implementation, digital twin technology can also be combined with simulation software to optimize the layout of the production line through virtual simulation. For example, when equipment in a certain area is congested or space utilization is low, the virtual model can generate optimization suggestions in real time and adjust the layout of the actual production line through an automatic control system. It should be noted that digital twin technology can not only be used for layout optimization, but also for fault monitoring of equipment status, providing support for the intelligent management of subsequent production line operations.

[0039] In some embodiments, the production line layout optimization can also be extended by combining multi-objective optimization techniques, for example, by considering the optimization of space utilization and production efficiency at the same time. Specifically, assuming that the total capacity of the production line is P and the number of workpieces produced per unit time is Q, the optimization objective can be expressed as: Among them, U is the space utilization, and α and β are weight parameters.

[0040] Therefore, through the production line layout optimization technology of the present invention, combined with simulation software modeling, prediction model and digital twin technology, efficient production support for the continuous plating process of automotive hardware can be achieved. The present invention not only significantly improves the utilization rate of workshop space, but also enhances the flexibility of the production line, providing technical support for adapting to the diverse needs of workpieces. Those skilled in the art can easily reproduce and implement the production line layout optimization technology of the present invention based on the above technical content and formulas.

[0041] An ultrasonic auxiliary device is set in the electrodeposition tank to optimize the distribution of current density during the electrodeposition process by adjusting the frequency and power parameters of the ultrasonic wave to improve the uniformity and density of the coating. The ultrasonic auxiliary device reduces the aggregation of bubbles generated during the electrodeposition process by adjusting the frequency and power parameters to improve the adhesion and uniformity of the coating.

[0042] In this embodiment, an ultrasonic auxiliary device is installed in the electrodeposition tank. The device works together with an ultrasonic generator, an ultrasonic probe and a control module to adjust the frequency and power of the ultrasonic wave during the electrodeposition process to optimize the distribution of current density in the electrodeposition tank and improve the uniformity and density of the coating.

[0043] Specifically, the main functions of the ultrasonic assisted device are reflected in the following aspects: Optimization of Electrodeposition Current Density by Ultrasonic Wave In this embodiment, the distribution of current density in the electrodeposition tank is regulated by an ultrasonic vibration field. The ultrasonic vibration generates periodic sound pressure changes in the electrodeposition tank, forming a sound field energy distribution, thereby affecting the transmission path of metal ions.

[0044] It should be noted that during the electrodeposition process, the change in current density J directly affects the coating thickness. Under the action of ultrasound, the optimization formula for current density distribution can be expressed as: Among them, J0 is the initial current density, A is the sound pressure amplitude, f is the ultrasonic frequency, and c is the sound velocity. By adjusting the ultrasonic frequency f and the sound pressure amplitude A, the local concentration of current density can be effectively reduced, making the deposition process of metal ions more uniform.

[0045] As an option, the frequency range of the ultrasonic wave can be set to 20-50 kHz, and the power range is 50-100 W. These parameter ranges are based on the results of experimental verification and can adapt to the deposition requirements of workpieces of different sizes and materials.

[0046] Ultrasonic wave inhibits bubble aggregation In some embodiments, the common problem of bubble aggregation during electrodeposition can significantly affect the adhesion performance and surface uniformity of the coating. This embodiment effectively inhibits the adhesion of bubbles to the electrode surface through the vibration of ultrasonic waves.

[0047] Specifically, the vibration and collapse of microbubbles formed by ultrasound in the electrolyte (i.e., the "cavitation effect") can peel the bubbles off the metal surface and avoid the destructive effect of bubble aggregation on the quality of the coating. As a possible implementation method, the intensity of the ultrasonic cavitation effect is related to the power density P. The power density formula is as follows: Where E is the energy transmitted by ultrasound per unit time; V is the volume of the liquid; By properly adjusting the power density of the ultrasonic wave, the efficiency of bubble removal can be significantly improved without damaging the coating. Densification effect of ultrasound on deposited particles It should be noted that the transmission path of metal ions under the action of ultrasound is more linear, which is conducive to the uniform accumulation and densification of deposited particles. In this embodiment, the coating generated by ultrasound-assisted electrodeposition technology has a denser microstructure, reducing the micropores and cracks common in traditional processes.

[0048] For example, the improvement in coating density can be quantified by the deposition efficiency η. The calculation formula for the deposition efficiency is: Where M is the mass of the metal, Q is the total amount of electricity passing through the electrode, F is the Faraday constant, and n is the number of ion charges. Under the action of ultrasound, the deposition efficiency is significantly improved, while the porosity of the metal deposition is reduced.

[0049] In one possible implementation, the ultrasonic auxiliary device is combined with a real-time monitoring system to dynamically adjust the frequency and power parameters of the ultrasonic wave according to the liquid flow state and electrolyte composition in the electrodeposition tank. For example, when the viscosity of the electrolyte is high, the power of the ultrasonic wave can be appropriately increased to enhance the vibration effect; when the temperature of the electrolyte is low, the frequency range can be adjusted to maintain the stability of the cavitation effect.

[0050] It should be noted that the dynamic adjustment of ultrasonic parameters depends on the real-time feedback of monitoring data, which can be achieved through sensors and control algorithms. For example, the sound pressure distribution and bubble concentration in the liquid can be detected in real time by acoustic sensors, and the detection data is used to optimize the control system.

[0051] In some embodiments, the ultrasonic assisted electrodeposition technology of the present invention is applicable to welding and plating of workpieces of various materials, such as zinc alloy, aluminum alloy and steel. Specifically, the metal ion deposition characteristics of different materials need to match different ultrasonic parameter settings. For example: For zinc alloy workpieces, a higher frequency (such as 40-50kHz) can be selected to improve the surface finish; For steel workpieces, a higher power density can be selected to enhance the adhesion of the coating.

[0052] For example, the thickness of the coating on the workpiece surface is controlled within the range of 5-15 microns, which can meet the requirements of automotive hardware for corrosion resistance and decorative appearance.

[0053] It should be noted that the ultrasonic assisted electrodeposition technology can also be combined with other electrodeposition optimization technologies, such as adding a dispersant to the electrolyte to further improve the transmission efficiency of metal ions, or realizing precise control of the ion migration path through an external magnetic field. In addition, the technical solution of the present invention is not only applicable to the rack plating process of automotive hardware, but can also be extended to aerospace parts and other high-demand metal surface treatment fields.

[0054] Green energy management includes: Power supply using solar photovoltaic power generation system and off-peak power of the grid; Storing excess solar power through energy storage devices and releasing it to meet production needs during peak electricity consumption; The energy dispatching system can optimize the allocation of electricity usage time and reduce energy consumption.

[0055] The energy storage device regulates the use of stored electricity through a dynamic charge and discharge management system, reducing dependence on external power sources.

[0056] In this embodiment, the green energy management system consists of the following core modules: solar photovoltaic power generation system, energy storage device, grid off-peak power access device and energy dispatch management system. Each module works together to achieve clean and efficient use of energy for the continuous rack plating production line; Design and application of solar photovoltaic power generation system In this embodiment, the solar photovoltaic power generation system is used as the main energy supply source, and its components include solar panels, inverters and photovoltaic controllers. The solar panels convert light energy into direct current, and the inverter converts direct current into alternating current for use in the production line.

[0057] As an option, the photovoltaic power generation system can be designed with different installed capacities according to the roof area of ​​the production workshop and the solar energy resource conditions. For example, in a photovoltaic power generation system with an installed capacity of 50kW, about 200kWh of electricity can be generated every day to meet the electricity demand of some production lines.

[0058] Specifically, the photovoltaic power generation system will give priority to providing clean electricity for the electrodeposition process during the day. If the electricity generated by photovoltaic power generation exceeds production demand, the excess electricity will be transmitted to the energy storage device for storage through the photovoltaic controller.

[0059] Dynamic charge and discharge management of energy storage devices The core function of the energy storage device is to store excess solar power and release it during peak power consumption to support the operation of the production line. In this embodiment, the energy storage device uses a lithium battery pack as an energy storage unit, combined with a dynamic charge and discharge management system to achieve flexible adjustment of energy supply.

[0060] The charging process of the energy storage device satisfies the following power balance relationship: P charge =P solar -P load Among them, P charge is the charging power of the energy storage device; P solar is the photovoltaic power generation power; P load is the real-time load power of the production line.

[0061] During peak hours, the energy storage device releases electrical energy according to the load demand of the production line. Its discharge power P discharge The following relations are satisfied: P discharge =P load -P solar If photovoltaic power generation cannot fully cover production needs, the energy storage device will release stored electricity to make up for the gap.

[0062] It should be noted that the dynamic charging and discharging process of the energy storage device is monitored and adjusted in real time through the management system to ensure the service life of the energy storage device and the stability of energy supply.

[0063] In some embodiments, the energy management system accesses low-price power from the grid during off-peak hours at night through an intelligent dispatching system to supplement the energy demand of the production line or charge the energy storage device. For example, during periods when the grid electricity price is low (e.g., 22:00-6:00), the system preferentially uses grid electricity to charge the energy storage device for use during the day.

[0064] As a possible implementation method, the grid access device includes an energy metering module and an electricity price detection module, which collects electricity price information in real time and dynamically adjusts the proportion of grid power usage. Specifically, the energy dispatching system will set a higher grid access priority during off-peak electricity price periods and switch to photovoltaic and energy storage power supply modes during peak daytime electricity price periods.

[0065] Optimization and implementation of energy dispatching system The energy dispatching system in this embodiment realizes the optimal dispatching of energy supply by comprehensively analyzing the load demand of the production line, photovoltaic power generation, energy storage status and grid electricity price information.

[0066] The optimization objective of the scheduling system can be expressed as: in, is the power obtained from the grid at time t; is the electricity price of the power grid at time t.

[0067] In one possible implementation, the dispatch system gives priority to photovoltaic power generation and energy storage power supply, and allocates the proportion of grid power supply between peak and trough power consumption through optimization algorithms, thereby significantly reducing energy costs.

[0068] It should be noted that the green energy management system of the present invention has strong adaptability and can be configured according to different production scales and energy conditions. For example: for situations where the production line is heavily loaded, the installed capacity of the photovoltaic power generation system or the capacity of the energy storage device can be increased; for areas with poor photovoltaic resources, the utilization ratio of the grid's off-peak electricity can be increased. In addition, this system is not only suitable for continuous plating production lines for automotive hardware, but can also be expanded to other manufacturing fields that require a stable energy supply, such as surface treatment of aerospace parts or high-energy-consuming electronic manufacturing.

[0069] Through the green energy management system of the present invention, combined with solar photovoltaic power generation, energy storage devices and optimized utilization of grid off-peak power, the clean and efficient energy supply of the production line is achieved, significantly reducing the dependence on external power sources. Those skilled in the art can flexibly adjust the energy management strategy based on the above disclosure and formula to achieve the best energy utilization effect, thereby ensuring the continuous and stable operation of the production line.

[0070] Composite surface modification technologies include: Enhance the bonding strength and wear resistance of the workpiece through surface modification before rack plating; After rack plating, the density and corrosion resistance of the coating are improved through strengthening treatment.

[0071] The surface modification process is an ion implantation process, and the strengthening process is a laser cladding process.

[0072] In this embodiment, by performing surface modification before rack plating and strengthening treatment after rack plating, the overall improvement of workpiece bonding, wear resistance, coating density, and corrosion resistance is achieved. Specifically, the present invention uses ion implantation as the surface modification treatment before rack plating, and strengthens the workpiece surface by high-energy ions, thereby enhancing the bonding between the coating and the substrate and the surface wear resistance; at the same time, a laser cladding process is introduced after rack plating, and the density and corrosion resistance of the coating are further improved by a high-energy laser beam. The present invention effectively improves the surface performance of automotive hardware by rationally designing and optimizing the composite surface modification technology, providing a guarantee for long-term use in complex working environments.

[0073] It should be noted that the composite surface modification technology of the present invention has high flexibility and is applicable to workpieces of various materials and shapes, and its core lies in the coordinated design of ion implantation process and laser cladding process. The technical content of the present invention is described in detail below in conjunction with specific embodiments.

[0074] In this embodiment, the composite surface modification technology mainly includes the following two stages: surface modification treatment before rack plating and strengthening treatment after rack plating.

[0075] Surface modification before rack plating (ion implantation process) In this embodiment, the ion implantation process is used to modify the surface of the workpiece before rack plating to enhance the bonding force between the coating and the substrate and improve the wear resistance of the workpiece surface. Specifically, the ion implantation process uses a high-energy ion beam to implant specific elements into the surface of the workpiece to form a strengthening layer.

[0076] As an option, the type of ions used for ion implantation can be selected based on the workpiece material and target performance requirements. For example: For steel workpieces, nitrogen ions (N +) To form a nitride layer to improve surface hardness and wear resistance; For aluminum alloy workpieces, titanium ions (Ti + ) or argon ions (Ar + ), enhance the bonding strength of the coating.

[0077] It should be noted that the key parameters in the ion implantation process include ion energy, implantation dose and implantation depth. For example, the ion energy range can be set to 50-200 keV, and the implantation dose range can be set to 1×10 16 ~1×10 18 ions / cm 2 , the injection depth d can be calculated by the following formula: Where E is the ion energy; Z is the atomic number of the workpiece matrix material; and n is the atomic density of the material.

[0078] Specifically, the thickness of the strengthening layer can be adjusted by controlling the injection depth to meet the usage requirements of different workpieces.

[0079] As a possible implementation method, the ion implantation equipment includes an ion source, an accelerator and a beam regulation system, wherein the beam regulation system is used to control the distribution uniformity of the ion beam to ensure that each area on the workpiece surface receives a consistent treatment effect.

[0080] In some embodiments, the ion implantation process may also be used in combination with other pretreatment techniques (such as sandblasting or chemical etching) to further improve the cleanliness and roughness of the workpiece surface, thereby improving the adhesion of the coating.

[0081] Strengthening treatment after rack plating (laser cladding process) In this embodiment, the laser cladding process is used to strengthen the coating of the workpiece after rack plating to improve the density and corrosion resistance of the coating. Laser cladding locally heats the coating surface through a high-energy laser beam to form a dense cladding layer.

[0082] It should be noted that the key control parameters in the laser cladding process include laser power, scanning speed and cladding layer thickness. The laser power P usually ranges from 500 to 2000W, the scanning speed v is 10 to 50mm / s, and the calculation formula for the cladding layer thickness h is: Among them, ρ is the density of the coating material; P is the laser power; v is the laser scanning speed.

[0083] Specifically, by optimizing the combination of laser power and scanning speed, high densification of the cladding layer can be achieved, thereby improving the anti-penetration ability and corrosion resistance of the coating.

[0084] As a possible implementation method, the laser cladding equipment includes a high-energy laser, a galvanometer scanning system and a cooling system. Among them, the galvanometer scanning system is used to control the scanning trajectory of the laser beam on the surface of the workpiece to ensure that the cladding layer evenly covers the coating surface.

[0085] In some embodiments, the laser cladding process may also be used in combination with alloy powder addition technology to further enhance the coating performance by evenly spreading corrosion-resistant alloy powder (such as nickel-based alloy powder) on the coating surface.

[0086] Synergistic Effect of Ion Implantation and Laser Cladding It should be noted that the ion implantation process and the laser cladding process have a significant synergistic effect in the present invention. Specifically, the ion implantation process forms a strengthening layer on the substrate surface, thereby enhancing the bonding strength of the coating and providing a stable foundation for subsequent laser cladding.

[0087] The laser cladding process further improves the protective effect of the ion implantation layer by densifying the coating.

[0088] For example, through the synergistic effect of ion implantation and laser cladding, comprehensive performance optimization can be achieved, with coating bonding strength increased by 30%, wear resistance increased by 20%, and corrosion resistance increased by 40%.

[0089] In some embodiments, the composite surface modification technology of the present invention can also be extended to the surface treatment of other complex parts. For example: In the field of aerospace, the heat resistance and oxidation resistance of high-temperature alloy parts are improved by ion implantation of tantalum ions and cladding of ceramic-based materials. On high-precision parts in electronic equipment, the fine surface structure can be protected by reducing the ion implantation dose and laser cladding power.

[0090] In addition, the composite surface modification technology of the present invention can also be combined with intelligent monitoring equipment to dynamically adjust process conditions to meet the processing requirements of different workpieces by real-time monitoring of key parameters in the ion implantation and laser cladding processes.

[0091] Therefore, through the composite surface modification technology of the present invention, combined with the ion implantation process before rack plating and the laser cladding process after rack plating, the bonding strength, wear resistance and density of the coating of automotive hardware are significantly improved, providing technical guarantee for long-term use in complex environments. Those skilled in the art can flexibly adjust the process parameters according to the above technical content and formula to achieve the best modification effect, thereby ensuring the high performance requirements of the workpiece surface.

[0092] Intelligent monitoring and operation and maintenance include an IoT-based monitoring system that collects temperature, vibration and power data of equipment in real time by installing sensors, and transmits the data to the operation and maintenance platform for analysis. The remote operation and maintenance platform uses equipment operation data and fault prediction models to warn of potential equipment failures.

[0093] In this embodiment, remote monitoring and operation and maintenance management of the equipment are achieved by real-time collection of equipment operation data, analysis of equipment status and combination with fault prediction models. Specifically, the present invention collects key parameters such as temperature, vibration, and power through sensors installed at key equipment locations, and transmits the collected data to a remote operation and maintenance platform for analysis. Based on real-time data, the operation and maintenance platform combines big data analysis technology and fault prediction models to identify the operating status of the equipment, predict potential faults, and provide early warning prompts so that maintenance measures can be taken in a timely manner, thereby reducing unplanned downtime and improving the operating efficiency of the production line.

[0094] It should be noted that the intelligent monitoring and operation and maintenance method of the present invention is applicable to various key equipment in the continuous rack plating production line of automotive hardware, and its characteristics lie in the accuracy of data collection and the high efficiency of fault prediction. The present invention is described in detail below in conjunction with specific embodiments.

[0095] The intelligent monitoring and operation and maintenance system mainly includes the following modules: data acquisition module, data transmission module, remote operation and maintenance platform and fault prediction model. Each module works together to form a closed-loop monitoring and management process.

[0096] In this embodiment, various types of sensors are installed on key equipment of the rack plating production line (such as electrodeposition tank, ultrasonic auxiliary device, energy dispatching device, etc.) to collect real-time operation data of the equipment. The type and installation location of the sensor are selected according to the performance characteristics and monitoring requirements of the equipment.

[0097] Specifically, the temperature sensor is used to monitor the operating temperature of the equipment, the vibration sensor is used to detect the vibration state of the equipment during operation, and the power sensor is used to collect the real-time power consumption data of the equipment. The collected raw data D(t) includes the following: D(t)={T(t),V(t),P(t)} Wherein, T(t) represents the temperature data of the device; V(t) represents the vibration data of the device; and P(t) represents the power consumption data of the device.

[0098] As an option, the temperature sensor can choose a thermocouple-based temperature measurement device with a measurement accuracy of ±0.1°C; the vibration sensor can use an accelerometer with a measurement range of ±10g; the power sensor can use a combination of current transformers and voltage sensors to achieve accurate monitoring of power consumption.

[0099] It should be noted that the data collected by the sensor is recorded at fixed time intervals, and the sampling frequency is determined according to the operating characteristics of the equipment. For example, the data collection of the vibration sensor can be set to a higher sampling frequency (such as 1kHz) to capture the transient characteristics of the equipment operation; and the sampling frequency of the power data can be set to 1Hz to meet the needs of energy consumption analysis.

[0100] Design and implementation of data transmission module The collected real-time data is transmitted to the remote operation and maintenance platform through the IoT communication module. Specifically, the communication module supports multiple transmission protocols, such as Wi-Fi, LoRa and 5G. The choice of communication method is determined by the workshop network environment and data volume requirements.

[0101] In one possible implementation, the collected data is transmitted to the cloud server via the MQTT (Message Queuing Telemetry Transport) protocol. The MQTT protocol is characterized by low bandwidth and high reliability, and is suitable for real-time data transmission of large-scale industrial equipment.

[0102] It should be noted that, in order to ensure the security of data transmission, this embodiment uses TLS (Transport Layer Security) encryption technology to encrypt data for transmission to prevent data tampering and leakage during transmission.

[0103] Design and implementation of remote operation and maintenance platform The remote operation and maintenance platform in this embodiment is responsible for storing, analyzing and visualizing the collected equipment operation data. The core functions of the platform include data monitoring, fault prediction and early warning prompts.

[0104] Specifically, the remote operation and maintenance platform monitors and analyzes the equipment status through the following steps: Data storage: Store the collected raw data in a relational database (such as MySQL or PostgreSQL) and index the data based on timestamps.

[0105] Data cleaning: Clean the raw data collected by the sensor to remove outliers and noise data.

[0106] Status analysis: Analyze the real-time operating status of the equipment based on the data after cleaning. For example, by analyzing the change trend of temperature data T(t), it can be determined whether the equipment is overheating.

[0107] It should be noted that the platform provides a visual interface, and the equipment operation status is displayed in the form of a curve chart or dashboard, which makes it easy for operators to understand the operation status of the equipment in real time. Design and implementation of fault prediction model In this embodiment, the fault prediction model is based on big data analysis technology and machine learning algorithms to predict potential equipment failures and issue early warning signals. The core of the model is to extract features and detect anomalies in equipment operation data.

[0108] Specifically, the fault prediction model uses the support vector machine (SVM) algorithm, and its prediction formula is: y=sign(w T φ(x)+b) Among them, x is the input feature vector, including the temperature, vibration and power data of the equipment; φ(x) is the feature mapping function; w and b are model parameters.

[0109] As a possible implementation, the input feature vector of the model may include the following: x=[T mean ,T std ,V mean ,V std ,P mean ,P std ] Among them, T mean and T std Respectively represent the mean and standard deviation of temperature data; V mean and V std Respectively represent the mean and standard deviation of vibration data; P mean and P std denote the mean and standard deviation of the power data, respectively.

[0110] The model classifies and judges the input features and outputs the operating status of the equipment (normal or abnormal). When an abnormality is predicted, the system automatically generates an early warning signal and notifies the operator.

[0111] In some embodiments, the intelligent monitoring and operation and maintenance method of the present invention can also be combined with predictive maintenance technology. For example, when the operating state of the equipment is close to the critical value of failure, the system can generate a maintenance plan in advance to reduce the unplanned downtime of the equipment.

[0112] In addition, the present invention can also be extended to the monitoring and operation and maintenance of other industrial equipment, such as the status monitoring of aerospace parts, the operation management of electronic manufacturing equipment, etc. By adjusting the sensor type and the parameter setting of the fault prediction model, the application requirements of different fields can be met.

[0113] Therefore, through the intelligent monitoring and operation and maintenance method of the present invention, combined with the Internet of Things monitoring system and the remote operation and maintenance platform, real-time monitoring of the equipment operation status and early prediction of potential failures are effectively achieved. Those skilled in the art can flexibly adjust the data collection and analysis methods according to the above technical content and formulas to adapt to the monitoring requirements of different equipment, thereby ensuring the efficient operation of the production line and the long-term stability of the equipment.

[0114] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for continuous rack plating of automotive hardware, characterized in that: include: Production line layout optimization: According to the size, shape and production requirements of the workpiece, computer simulation and dynamic adjustment technology are used to optimize the production line layout, optimize the utilization of workshop space, and provide a production environment for the continuous rack plating process; Ultrasonic assisted electrodeposition: Based on the optimization of production line layout, ultrasonic assisted electrodeposition technology is used to improve the uniformity and density of the coating by controlling the current density distribution in the electrodeposition tank; Green energy management: Based on the energy demand of the production line, a comprehensive energy management system is established, combining the solar photovoltaic power generation system and energy storage device. Through energy distribution, the daytime stored energy and the night-time off-peak power are coordinated to support the operation of the electrodeposition process; Composite surface modification technology: In the stages before and after the rack plating process, ion implantation technology is used for surface pretreatment according to the properties of the workpiece, and laser cladding technology is used to strengthen the bonding force of the coating, thereby improving the wear resistance and surface performance of the workpiece; Intelligent monitoring and operation and maintenance: Based on the Internet of Things monitoring system, equipment operation data is collected in real time during the production process. Through the remote operation and maintenance platform combined with big data analysis and fault prediction technology, the production process is dynamically optimized, potential faults are identified and early warnings are issued.

2. A method for continuous rack plating of automotive hardware according to claim 1, characterized in that: The production line layout optimization comprises the following steps: Model the workpiece size and production batch through simulation software to analyze and optimize the workpiece arrangement; Use the prediction model to predict the trend of workpiece size changes and dynamically adjust the production line layout based on the prediction results; Build a production line model based on digital twin technology, monitor the operating status of the workshop, and optimize the production line layout based on the monitoring results.

3. A method for continuous rack plating of automotive hardware according to claim 1, characterized in that: An ultrasonic auxiliary device is set in the electrodeposition tank. By adjusting the frequency and power parameters of the ultrasonic wave, the distribution of current density during the electrodeposition process is optimized to improve the uniformity and density of the coating.

4. A method for continuous rack plating of automotive hardware according to claim 3, characterized in that: The ultrasonic auxiliary device reduces the bubble aggregation generated during the electrodeposition process by adjusting the frequency and power parameters, so as to improve the adhesion performance and uniformity of the coating.

5. A method for continuous rack plating of automotive hardware according to claim 1, characterized in that: The green energy management includes: Power supply using solar photovoltaic power generation system and off-peak power of the grid; Storing excess solar power through energy storage devices and releasing it to meet production needs during peak electricity consumption; The energy dispatching system can optimize the allocation of electricity usage time and reduce energy consumption.

6. A method for continuous rack plating of automotive hardware according to claim 5, characterized in that: The energy storage device adjusts the use of stored energy power through a dynamic charge and discharge management system, thereby reducing dependence on an external power source.

7. A method for continuous rack plating of automotive hardware according to claim 1, characterized in that: The composite surface modification technology includes: Enhance the bonding strength and wear resistance of the workpiece through surface modification before rack plating; After rack plating, strengthening treatment is performed to improve the density and corrosion resistance of the coating.

8. A method for continuous rack plating of automotive hardware according to claim 7, characterized in that: The surface modification process is an ion implantation process, and the strengthening process is a laser cladding process.

9. A method for continuous rack plating of automotive hardware according to claim 1, characterized in that: The intelligent monitoring and operation and maintenance includes a monitoring system based on the Internet of Things, which collects the temperature, vibration and power data of the equipment in real time by installing sensors, and transmits the data to the operation and maintenance platform for analysis.

10. A method for continuous rack plating of automotive hardware according to claim 9, characterized in that: The remote operation and maintenance platform provides early warning of potential equipment failures based on equipment operation data and combined with a fault prediction model.

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