Liquid medicine manufacturing process monitoring method and system based on cyanide-free cadmium electroplating

Abstract

The invention provides a liquid medicine manufacturing process monitoring method and system based on cyanide-free cadmium electroplating, temperature, solution concentration (cadmium ion concentration and HEDP concentration) and pH value data are collected in real time through a multi-parameter sensor module, big data analysis is performed in combination with a mathematical model based on an Arrhenius equation and a chemical equilibrium principle, and the liquid medicine manufacturing process monitoring system based on cyanide-free cadmium electroplating is obtained. And negative feedback regulation of the temperature, the material adding speed and the pH value is realized by utilizing a PID (Proportion Integration Differentiation) or a fuzzy control algorithm. According to the system, the thickness uniformity fluctuation of the plating layer can be controlled within + / -5%, the stability of the plating solution is improved by 40%, the production efficiency is improved by 30%, and the problems of unstable quality and low production efficiency of the traditional cyanide-free cadmium electroplating liquid medicine are effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of cyanide-free electroplating, and in particular to a method and system for monitoring a cyanide-free cadmium electroplating solution production process. Background Art

[0002] In the cyanide-free cadmium electroplating process, the quality of the chemical solution directly affects the performance of the coating. The traditional production method has the following technical bottlenecks: Rough parameter control: temperature and pH value are adjusted manually based on experience. Temperature fluctuation exceeds ±2°C and pH value deviation exceeds ±0.2, resulting in coarse crystallization of the coating and surface roughness greater than 1.5μm. Imbalance in material ratio: When the ratio of HEDP to cadmium ion concentration deviates from the optimal value (n=3), the complex concentration in the plating solution fluctuates by more than 10%, causing the coating to become more brittle. Lack of dynamic adjustment: Unable to respond in real time to fluctuations in raw material purity (e.g., cadmium salt purity <99.5%) and parameter drift caused by equipment aging, resulting in a batch qualification rate of only 75%-80%; Low data utilization: A parameter-quality correlation model had not been established, making it impossible to quickly locate the root cause of production anomalies. As a result, downtime investigation time accounted for 15%.

[0003] Existing technologies, such as the cyanide-free electroplating monitoring system disclosed in CN201910345678.9, only implement single temperature closed-loop control, do not integrate the coordinated adjustment of multiple parameters such as concentration and pH value, and do not construct a predictive model based on chemical principles, making it difficult to adapt to complex reaction systems. Summary of the Invention

[0004] The present invention provides a method and system for monitoring the production process of a cyanide-free cadmium electroplating solution, aiming to solve the problems raised by the above-mentioned background technology.

[0005] The present invention is achieved by providing a monitoring system for the production process of a cyanide-free cadmium electroplating solution, comprising: Multi-parameter sensor module: equipped with a temperature sensor and a concentration sensor array, which includes a cadmium ion sensor, a HEDP concentration sensor, and a pH sensor, for real-time acquisition of the temperature T during the preparation of the solution, the concentration of each component in the solution [Cd 2+ ], [HEDP] and pH data; Big Data Processing and Analysis Module: stores a mathematical model based on the Arrhenius equation, chemical equilibrium principles, and experimental data. The model includes: Temperature and reaction rate relationship model: in, The reaction rate constant is used to measure the speed of a chemical reaction. The larger the value, the faster the reaction rate. is the prefactor, Reaction activation energy, Molar gas constant, Thermodynamic temperature, Reaction rate, that is, the decrease in reactant concentration or the increase in product concentration per unit time, is used to intuitively describe the speed at which a chemical reaction proceeds. The proportional constant is used to establish a quantitative relationship between the reaction rate constant k and the reaction rate v. Its value depends on the specific conditions and unit settings of the reaction system. It is measured by indicators such as production efficiency, the amount of liquid medicine produced per unit time or the amount of reaction completed. It is a constant related to production equipment and process, reflecting the impact of production equipment performance and process operating conditions on the relationship between production efficiency and reaction rate; Relationship model between concentration and plating solution stability: ; The relationship model between pH value and ion existence form: ; Quality indicator prediction model: ; Negative feedback control execution module: Based on the mathematical model and real-time collected data, the temperature control device, material addition device and pH adjustment device are dynamically adjusted through PID control algorithm or fuzzy control algorithm to maintain each parameter within the preset high-quality production range.

[0006] Preferably, the big data processing and analysis module further includes: Historical database: stores at least 12 months of historical data on production parameters and quality indicators; Real-time prediction unit: predicts the uniformity of coating thickness based on the mathematical model and real-time data surface roughness , plating solution stability Quality indicators; Deviation calculation unit: calculates the deviation between the predicted value and the target value ; Parameter optimization unit: Calculate the temperature, concentration, and pH value optimization parameter set that makes the quality index closest to the target value through gradient descent algorithm or genetic algorithm.

[0007] Preferably, the regulation logic of the negative feedback control execution module includes: when and When the cooling device is turned on, adjust the temperature to ; when When, according to , calculate the required adjustment or Concentration, and control the peristaltic pump to add materials; when When, based on Calculate the amount of acid and alkali to be added and adjust it by adding acid / alkali pump .

[0008] Preferably, the monitoring method of the cyanide-free cadmium electroplating solution production process monitoring system comprises the following steps: Real-time parameter acquisition: temperature T, solution concentration [Cd 2+ ], [HEDP] and pH value; Mathematical model calculation: Substitute the collected parameters into the mathematical model to calculate the current reaction rate v, plating solution stability S, and coating quality index U thickness ; Dynamic deviation analysis: Compare the calculated value with the preset target value to generate temperature deviation ΔT and concentration deviation ΔC, pH deviation ΔpH; Negative feedback regulation: Based on the deviation, the temperature, material addition rate and pH value are adjusted through PID control algorithm or fuzzy control algorithm to make each parameter approach the optimized value; Model adaptive optimization: After each production batch, the mathematical model parameters are updated according to the actual quality data to improve the prediction accuracy.

[0009] Preferably, the negative feedback regulation step further comprises: When ΔT>1°C is detected for three consecutive sampling periods, the temperature warning mechanism is triggered and the backup temperature control system is activated; When |ΔC|>5%, the concentration sensor will be automatically calibrated and the material addition speed will be adjusted; When ΔpH>0.1, the dual-pump coordinated adjustment mechanism is activated, first quickly adjusting the pH and then slowly fine-tuning it to the target value.

[0010] Preferably, the model adaptive optimization step includes: Use random forest algorithm to analyze historical data and identify key parameters affecting quality; Conduct parameter sensitivity analysis every quarter and update model weight coefficients; When the deviation between the actual quality indicator and the predicted value continues to exceed 10%, the model reconstruction process is triggered.

[0011] Preferably, a computer-readable storage medium stores a computer program thereon, characterized in that when the computer program is executed by a processor, the steps of the method according to any one of claims 4 to 6 are implemented.

[0012] Due to the adoption of the above solution, the beneficial effects of the present invention are: quality stability is improved: the uniformity of the coating thickness U thickness Up to 95%±3%, surface roughness R a<0.8μm, the plating solution stability S is increased to 92%; Improved production efficiency: Single-batch production cycle shortened by 25%, material waste reduced by 18%, and annual production capacity increased by 30%; Reduced energy consumption: The temperature control system saves 22% of energy and reduces acid and alkali consumption by 20%, meeting green production requirements; Improved intelligence level: A shift from "experience-based control" to "model-driven control" has been achieved, with abnormal warning response time less than 10s and fault location accuracy greater than 95%. DETAILED DESCRIPTION

[0013] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0014] The monitoring system for the production process of cyanide-free cadmium electroplating solution includes: a multi-parameter sensor module: equipped with a temperature sensor, a concentration sensor array, which includes a cadmium ion sensor, a HEDP concentration sensor and a pH sensor, for real-time acquisition of the temperature T during the production process of the solution, the concentration of each component in the solution [Cd 2+ ], [HEDP] and pH value data; Big data processing and analysis module: stores a mathematical model based on the Arrhenius equation, chemical equilibrium principle and experimental data, the model includes: Temperature and reaction rate relationship model: in, The reaction rate constant is used to measure the speed of a chemical reaction. The larger the value, the faster the reaction rate. is the prefactor, Reaction activation energy, Molar gas constant, Thermodynamic temperature, Reaction rate, that is, the decrease in reactant concentration or the increase in product concentration per unit time, is used to intuitively describe the speed at which a chemical reaction proceeds. The proportional constant is used to establish a quantitative relationship between the reaction rate constant k and the reaction rate v. Its value depends on the specific conditions and unit settings of the reaction system. It is measured by indicators such as production efficiency, the amount of liquid medicine produced per unit time or the amount of reaction completed. It is a constant related to production equipment and process, reflecting the impact of production equipment performance and process operating conditions on the relationship between production efficiency and reaction rate; Relationship model between concentration and plating solution stability: ; The relationship model between pH value and ion existence form: ; Quality indicator prediction model: ; Negative feedback control execution module: Based on the mathematical model and real-time collected data, the temperature control device, material addition device and pH adjustment device are dynamically adjusted through PID control algorithm or fuzzy control algorithm to maintain each parameter within the preset high-quality production range.

[0015] The big data processing and analysis module further includes: Historical database: stores at least 12 months of historical data on production parameters and quality indicators; Real-time prediction unit: predicts the uniformity of coating thickness based on the mathematical model and real-time data surface roughness , plating solution stability Quality indicators; Deviation calculation unit: calculates the deviation between the predicted value and the target value ; Parameter optimization unit: Calculate the temperature, concentration, and pH value optimization parameter set that makes the quality index closest to the target value through gradient descent algorithm or genetic algorithm.

[0016] The regulation logic of the negative feedback control execution module includes: when and When the cooling device is turned on, adjust the temperature to ; when When, according to , calculate the required adjustment or Concentration, and control the peristaltic pump to add materials; when When, based on Calculate the amount of acid and alkali to be added and adjust it by adding acid / alkali pump .

[0017] The monitoring method of the cyanide-free cadmium electroplating solution production process monitoring system comprises the following steps: Real-time parameter acquisition: temperature T, solution concentration [Cd 2+ ], [HEDP] and pH value; Mathematical model calculation: Substitute the collected parameters into the mathematical model to calculate the current reaction rate v, plating solution stability S, and coating quality index U thickness ; Dynamic deviation analysis: Compare the calculated value with the preset target value to generate temperature deviation ΔT and concentration deviation ΔC, pH deviation ΔpH; Negative feedback regulation: Based on the deviation, the temperature, material addition rate and pH value are adjusted through PID control algorithm or fuzzy control algorithm to make each parameter approach the optimized value; Model adaptive optimization: After each production batch, the mathematical model parameters are updated according to the actual quality data to improve the prediction accuracy.

[0018] The negative feedback regulation step further comprises: When ΔT>1°C is detected for three consecutive sampling periods, the temperature warning mechanism is triggered and the backup temperature control system is activated; When |ΔC|>5%, the concentration sensor will be automatically calibrated and the material addition speed will be adjusted; When ΔpH>0.1, the dual-pump coordinated adjustment mechanism is activated, first quickly adjusting the pH and then slowly fine-tuning it to the target value.

[0019] The model adaptive optimization step includes: Use random forest algorithm to analyze historical data and identify key parameters affecting quality; Conduct parameter sensitivity analysis every quarter and update model weight coefficients; When the deviation between the actual quality indicator and the predicted value continues to exceed 10%, the model reconstruction process is triggered.

[0020] A computer-readable storage medium having a computer program stored thereon, characterized in that when the computer program is executed by a processor, the steps of the method according to any one of claims 4 to 6 are implemented.

[0021] Example 1 Taking the production of 3000L cyanide-free cadmium electroplating solution in a certain electroplating plant as an example, the specific implementation steps are as follows: Step 1: System Initialization Set process parameters: T = 50 ± 0.5 ° C (323K), [Cd 2+ ]=0.2mol / L, [HEDP]=0.65mol / L (n=3.25), pH=12.2±0.05; Model parameter configuration: E a =52kJ / mol, A=1.8×10 9 s -1 , K=5.6×10 13 , C3=95, C4=0.8.

[0022] Step 2: Real-time parameter acquisition The PT100 sensor detected the reaction temperature T = 50.8 ° C (323.8 K), and the cadmium ion electrode measured [Cd 2+]=0.21mol / L, the HEDP concentration sensor shows 0.62mol / L, and the pH electrode detects a value of 12.1; The data is converted from analog to digital by the PLC and then transmitted to an industrial computer (CPU i7-12700, memory 16GB).

[0023] Step 3: Mathematical model calculation Reaction rate constant k = 1.8 × 10 9 e^(-52000 / (8.314×323.8))≈3.2×10 -4 s -1 ; Reaction rate v = 0.5 × 3.2 × 10 -4 =1.6×10 -4 mol / (L・s); Complex concentration [Cd (HEDP)3] - =K・[Cd 2+ ]・[HEDP] 3 =5.6×10 13 ×0.21×0.62 3 ≈2.7×10 12 mol / L; Plating solution stability S=0.03×2.7×10¹²≈8.1×10 10 (dimensionless); Coating thickness uniformity U thickness =95-0.8×(323.8-323) 2 =95-0.512=94.488%.

[0024] Step 4: Dynamic Deviation Analysis Temperature deviation ΔT=50.8-50=0.8℃>0.5℃; U thickness =94.49%<target value 95%; Plating solution stability S=8.1×10 10 <Standard value 8.5×10 10 .

[0025] Step 5: Negative Feedback Regulation Temperature regulation: Start the cooling device, and the PID controller outputs the regulation amount: u(t)=2.5×0.8+0.1×∫0.8dt+5×(0.8-0.3) / Δt Concentration adjustment: Calculate the amount of HEDP to be added: Δ[HEDP]=0.65-0.62=0.03mol / L, amount added=0.03×3000=90mol HEDP solution (concentration 1 mol / L) was added by a peristaltic pump at a rate of 5 mL / min. After 45 minutes, [HEDP] = 0.65 mol / L; pH adjustment: Current pH = 12.1, target pH 12.2, calculation shows that 5% KOH solution needs to be added: [OH - ]=10^(12.2-14)=1.58×10 -2 mol / L, current [OH - ]=10^(12.1-14)=1.26×10 - 2 mol / L Δ[OH - ]=0.32×10 -2 mol / L, added amount = 0.32×10 -2 ×3000×56 / 5%≈10752g Coordinated adjustment of the two pumps: first make a rough adjustment at 100 mL / min to pH = 12.18, then make a fine adjustment at 10 mL / min to 12.2.

[0026] Step 6: Model Adaptive Optimization After the batch is completed, the measured U thickness =95.2%, with a deviation of 0.72% from the predicted value, and the updated C4=0.82; The historical database has added this batch of data (the cumulative data volume for 12 months is 1.2×10 5 strip).

[0027] Implementation effect: After this batch of solution is used for electroplating, the uniformity of the coating thickness reaches 95.2%, the surface roughness is 0.75μm, and the plating solution can be used continuously for 30 days without precipitation; Compared with traditional processes, the production cycle is shortened from 4 hours to 3 hours, HEDP consumption is reduced by 15%, and energy consumption is reduced by 20%.

[0028] The above examples demonstrate that the present invention achieves high-quality, high-efficiency production of cyanide-free cadmium electroplating solutions through precise parameter monitoring, chemically based model calculations, and intelligent negative feedback regulation. Those skilled in the art may adjust the model parameters and control strategies based on actual production requirements, and all such adjustments are considered within the scope of the present invention.

[0029] The above description of the embodiments is intended to facilitate the understanding and use of the present invention by those skilled in the art. It is obvious that those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without having to go through creative work. Therefore, the present invention is not limited to the above embodiments. Improvements and modifications made by those skilled in the art based on the principles of the present invention without departing from the scope of the present invention should be within the scope of protection of the present invention. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. Based on the cyanide-free cadmium electroplating solution production process monitoring system, it is characterized by: include: Multi-parameter sensor module: equipped with a temperature sensor and a concentration sensor array, including a cadmium ion sensor, a HEDP concentration sensor, and a pH sensor, which is used to collect the temperature T during the potion making process and the concentration of each component in the solution in real time. and pH data; Big Data Processing and Analysis Module: stores a mathematical model based on the Arrhenius equation, chemical equilibrium principles, and experimental data. The model includes: Temperature and reaction rate relationship model: in, The reaction rate constant is used to measure the speed of a chemical reaction. The larger the value, the faster the reaction rate. is the prefactor, Reaction activation energy, Molar gas constant, Thermodynamic temperature, Reaction rate, that is, the decrease in reactant concentration or the increase in product concentration per unit time, is used to intuitively describe the speed at which a chemical reaction proceeds. The proportional constant is used to establish a quantitative relationship between the reaction rate constant k and the reaction rate v. Its value depends on the specific conditions and unit settings of the reaction system. It is measured by indicators such as production efficiency, the amount of liquid medicine produced per unit time or the amount of reaction completed. It is a constant related to production equipment and process, reflecting the impact of production equipment performance and process operating conditions on the relationship between production efficiency and reaction rate; Relationship model between concentration and plating solution stability: ; The relationship model between pH value and ion existence form: ; Quality indicator prediction model: ; Negative feedback control execution module: Based on the mathematical model and real-time collected data, the temperature control device, material addition device and pH adjustment device are dynamically adjusted through PID control algorithm or fuzzy control algorithm to maintain each parameter within the preset high-quality production range.

2. The system for monitoring the production process of a cyanide-free cadmium electroplating solution according to claim 1, wherein: The big data processing and analysis module further includes: Historical database: stores at least 12 months of historical data on production parameters and quality indicators; Real-time prediction unit: predicts the uniformity of coating thickness based on the mathematical model and real-time data surface roughness , plating solution stability Quality indicators; Deviation calculation unit: calculates the deviation between the predicted value and the target value ; Parameter optimization unit: Calculate the temperature, concentration, and pH value optimization parameter set that makes the quality index closest to the target value through gradient descent algorithm or genetic algorithm.

3. The system for monitoring the production process of a cyanide-free cadmium electroplating solution according to claim 2, wherein: The regulation logic of the negative feedback control execution module includes: when and When the cooling device is turned on, adjust the temperature to ; when When, according to , calculate the required adjustment or Concentration, and control the peristaltic pump to add materials; when When, based on Calculate the amount of acid and alkali to be added and adjust it by adding acid / alkali pump .

4. The monitoring method of the cyanide-free cadmium electroplating solution production process monitoring system according to claims 1-3, characterized in that: The following steps are involved: Real-time parameter acquisition: temperature T, solution concentration [Cd 2+ ], [HEDP] and pH value; Mathematical model calculation: Substitute the collected parameters into the mathematical model to calculate the current reaction rate v, plating solution stability S, and coating quality index U thickness ; Dynamic deviation analysis: Compare the calculated value with the preset target value to generate temperature deviation ΔT and concentration deviation ΔC, pH deviation ΔpH; Negative feedback regulation: Based on the deviation, the temperature, material addition rate and pH value are adjusted through PID control algorithm or fuzzy control algorithm to make each parameter approach the optimized value; Model adaptive optimization: After each production batch, the mathematical model parameters are updated according to the actual quality data to improve the prediction accuracy.

5. The monitoring method of the cyanide-free cadmium electroplating solution production process monitoring system according to claim 4, characterized in that: The negative feedback regulation step further comprises: When ΔT>1°C is detected for three consecutive sampling periods, the temperature warning mechanism is triggered and the backup temperature control system is activated; When |ΔC|>5%, the concentration sensor will be automatically calibrated and the material addition speed will be adjusted; When ΔpH>0.1, the dual-pump coordinated adjustment mechanism is activated, first quickly adjusting the pH and then slowly fine-tuning it to the target value.

6. The monitoring method of the cyanide-free cadmium electroplating solution production process monitoring system according to claim 5, characterized in that: The model adaptive optimization step includes: Use random forest algorithm to analyze historical data and identify key parameters affecting quality; Conduct parameter sensitivity analysis every quarter and update model weight coefficients; When the deviation between the actual quality indicator and the predicted value continues to exceed 10%, the model reconstruction process is triggered.

7. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method according to any one of claims 4 to 6 are implemented.

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