An online monitoring system for electrolytic coloring

Abstract

This invention relates to the field of electrolytic oxidation technology, and in particular to an online monitoring system for electrolytic coloring. It includes: a power calculation module, a power supply module, an electrolytic cell, a stirrer, a heat exchanger, and a cooling device. The power calculation module is connected to the power supply module, the power supply module is connected to the electrolytic cell, the electrolytic cell is connected to the heat exchanger, and the heat exchanger is connected to the cooling device. An electrolyte is provided inside the electrolytic cell, and the stirrer is located inside the electrolytic cell. A monitoring unit is used to detect the surface area of ​​the workpiece being processed and the parameters of the electrolyte in real time. A control unit is used to control the output current of the power supply module based on the surface area of ​​the workpiece. This invention, through dynamic real-time monitoring of the metal electrolytic coloring process, fully ensures the production quality of the electrolyte and the workpiece. Furthermore, by monitoring relevant parameters during the production process and automatically adjusting them, it prevents local defects in the finished workpiece and improves the processing quality.

Description

Technical Field

[0001] This invention relates to the field of electrolytic oxidation technology, and in particular to an online monitoring system for electrolytic coloring. Background Technology

[0002] Plasma-based special oxidation, or TPEO for short, is also known as plasma electrolytic oxidation (PEO). It employs an organic salt charge short-circuit method for in-tank coloring. The specific formulation consists of a conductive solution composed of organic substances such as silicon, vanadium, sodium, fluorine, glass water, EDTA, and iron. The basic principle and characteristics of this technology are based on hard anodizing, utilizing arc discharge to enhance and activate the reaction between valve metal ions on the anode and oxygen ions in the chemical solution. This results in the deposition of a strengthening film on the surface of workpieces made of special valve metals such as aluminum, titanium, and magnesium, and their alloys. This method involves applying a high voltage to the workpiece using a dedicated special oxidation power source, causing the metal on the workpiece surface to interact with the electrolyte solution, forming a special discharge on the workpiece surface. Under the influence of high temperature and electric field, a ceramic film forms on the metal surface, achieving the goals of surface strengthening, significantly increased hardness, and improved wear resistance, corrosion resistance, pressure resistance, insulation, and high-temperature impact resistance.

[0003] However, existing technologies do not provide precise control over the electrolytic coloring process of metals. Due to the numerous causes of defects in the finished product, including the influence of impurities in the electrolyte solution and multiple influencing factors such as pH value, it is necessary to effectively monitor each stage of the electrolysis process in real time. Current methods rely on testing the finished product after processing, and there is no technical solution for real-time monitoring during the production process. This leads to defects in the finished product, resulting in waste of raw materials and increased costs. Therefore, how to provide an online monitoring system for electrolytic coloring is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0004] The purpose of this invention is to provide an online monitoring system for electrolytic coloring. This invention dynamically monitors the metal electrolytic coloring process in real time, ensuring the production quality of the electrolyte and the workpiece. Furthermore, while monitoring relevant parameters during the production process, it automatically adjusts them, further preventing local defects in the finished workpiece and effectively improving the processing quality.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] An online monitoring system for electrolytic coloring includes: a power calculation module, a power supply module, an electrolytic cell, a stirrer, a heat exchanger, and a cooling device. The power calculation module is connected to the power supply module, the power supply module is connected to the electrolytic cell, the electrolytic cell is connected to the heat exchanger, the heat exchanger is connected to the cooling device, an electrolyte is provided in the electrolytic cell, and the stirrer is disposed in the electrolytic cell.

[0007] Also includes:

[0008] A monitoring unit is used to detect the surface area S of the workpiece being processed and the parameter information of the electrolyte in real time.

[0009] Control unit, the control unit being used to control the output current of the power module according to the surface area S of the workpiece;

[0010] The control unit is configured with a preset workpiece surface area matrix T0 and a preset power module output current matrix A. For the preset power module output current matrix A, A(A1,A2,A3,A4) is set, where A1 is the first preset power module output current, A2 is the second preset power module output current, A3 is the third preset power module output current, and A4 is the fourth preset power module output current, and A1 < A2 < A3 < A4.

[0011] For the preset workpiece surface area matrix T0, set T0(T01,T02,T03,T04), where T01 is the first preset workpiece surface area, T02 is the second preset workpiece surface area, T03 is the third preset workpiece surface area, T04 is the fourth preset workpiece surface area, and T01 < T02 < T03 < T04.

[0012] The control unit is used to select the corresponding power module output current as the control power module output current according to the relationship between S and the preset workpiece surface area matrix T0.

[0013] When S < T01, the first preset power module output current A1 is selected as the output current to control the power module.

[0014] When T01≤S<T02, the second preset power module output current A2 is selected as the output current for controlling the power module;

[0015] When T02≤S<T03, the output current A3 of the third preset power module is selected as the output current for controlling the power module.

[0016] When T03≤S<T04, the output current A4 of the fourth preset power module is selected as the output current for controlling the power module.

[0017] In some embodiments of this application, the parameter information of the electrolyte includes the temperature K1 at the lowest liquid level and the temperature K2 at the highest liquid level of the electrolyte;

[0018] The control unit is also equipped with a preset electrolyte average temperature matrix R0 and a preset power module output current correction coefficient matrix B. For the preset power module output current correction coefficient matrix B, B(B1,B2,B3,B4) is set, where B1 is the first preset power module output current correction coefficient, B2 is the second preset power module output current correction coefficient, B3 is the third preset power module output current correction coefficient, and B4 is the fourth preset power module output current correction coefficient, and 1 < B1 < B2 < B3 < B4 < 1.5;

[0019] For the preset electrolyte average temperature matrix R0, set R0(R01,R02,R03,R04), where R01 is the first preset electrolyte average temperature, R02 is the second preset electrolyte average temperature, R03 is the third preset electrolyte average temperature, and R04 is the fourth preset electrolyte average temperature, and R01 < R02 < R03 < R04.

[0020] The control unit is also used to select the corresponding power module output current correction coefficient according to the relationship between K1 and K2 and the preset electrolyte average temperature matrix R0, so as to correct the output current of each preset power module.

[0021] When (K1+K2) / 2<R01, the fourth preset power module output current correction coefficient B4 is selected to correct the first preset power module output current A1. The corrected power module output current is A1*B4.

[0022] When R01≤(K1+K2) / 2<R02, the third preset power module output current correction coefficient B3 is selected to correct the second preset power module output current A2. The corrected power module output current is A2*B3.

[0023] When R02≤(K1+K2) / 2<R03, the second preset power module output current correction coefficient B2 is selected to correct the third preset power module output current A3. The corrected power module output current is A3*B2.

[0024] When R03≤(K1+K2) / 2<R04, the first preset power module output current correction coefficient B1 is selected to correct the fourth preset power module output current A4, and the corrected power module output current is A4*B1.

[0025] In some embodiments of this application, the power module adopts a soft-start method when supplying power;

[0026] The control unit also has a preset voltage rise time matrix Y0, which is set as Y0(Y01,Y02,Y03,Y04), where Y01 is the first preset voltage rise time, Y02 is the second preset voltage rise time, Y03 is the third preset voltage rise time, and Y04 is the fourth preset voltage rise time, and 10s < Y01 < Y02 < Y03 < Y04 < 15s;

[0027] The control unit is also used to select the corresponding voltage rise time as the boost time for soft start of the power module based on the corrected output current of each power module.

[0028] When the corrected power module output current is A1*B4, the fourth preset voltage rise time Y04 is selected as the boost time for the power module soft start.

[0029] When the corrected power module output current is A2*B3, the third preset voltage rise time Y03 is selected as the boost time for the soft start of the power module.

[0030] When the corrected power module output current is A3*B2, the second preset voltage rise time Y02 is selected as the boost time for the soft start of the power module.

[0031] When the corrected power module output current is A4*B1, the first preset voltage rise time Y01 is selected as the boost time for the soft start of the power module.

[0032] In some embodiments of this application, the monitoring unit is further configured to monitor the oxidation time in real time and calculate the surface oxide film thickness d of the workpiece based on the oxidation time; wherein the surface oxide film thickness d of the workpiece is calculated using the following formula:

[0033] d = K * (I / s) * t;

[0034] In the formula, d is the thickness of the surface oxide film, K is a coefficient, which is taken as 0.3, I is the output current of the power module, s is the surface area of ​​the workpiece, and t is the oxidation time;

[0035] The control unit is also used to determine whether the workpiece is qualified for electrolytic coloring based on the comparison between the surface oxide film thickness d of the workpiece and the preset standard surface oxide film thickness value D of the workpiece.

[0036] When d=D, the electrolytic coloring of the workpiece is deemed qualified;

[0037] When d < D or d > D, the electrolytic coloring of the workpiece is determined to be unqualified.

[0038] In some embodiments of this application, the control unit is provided with an alarm unit, and the control unit is also used to issue a real-time alarm through the alarm unit when it is determined that the electrolytic coloring of the workpiece is unqualified.

[0039] In some embodiments of this application, the control unit is further configured to base its calculations on the average value Q of K1 and K2. t To determine whether the electrolytic cell has malfunctioned, an effective temperature sequence is obtained, where t is an integer ≥ 1;

[0040] The control unit is set to a valid judgment value of Z. a And the judgment thresholds X and Z a =Q a -Q a-1 ;

[0041] The control unit is also used to control Z a Compare with X, when Z a When Z ≥ X, a The effective temperature series is not included, and Z is deleted. a When Z a When <X, Z a The effective temperature series is included in the calculation. The effective temperature series is set as {Mb}, where b is a positive integer; where 1≤a≤t and a is an integer, and X>0.

[0042] In some embodiments of this application, the control unit is further configured to calculate a compensation parameter V, wherein V = (H j-1 -H j-2 ) / (H j -H j-1 ), H j ∈{Mb}, j≥3 and j is an integer;

[0043] When (H) j-1 -H j-2 ) > 0 and (H j -H j-1 When ) > 0, the compensated temperature value is g = H j -|V|;

[0044] When (H) j-1 -H j-2 ) > 0 and (H j -H j-1 When ) < 0, the compensated temperature value is g = H j +|V|;

[0045] When (H) j-1 -H j-2 ) < 0 and (H j -Hj-1 When ) < 0, the compensated temperature value is g = H j +|V|;

[0046] When (H) j-1 -H j-2 ) < 0 and (H j -H j-1 When ) > 0, the compensated temperature value is g = H j -|V|;

[0047] When (H) j-1 -H j-2 When ) = 0, the compensated temperature value is g = H j ;

[0048] When (H) j -H j-1 When ) = 0, the compensated temperature value is g = H j ;

[0049] The control unit is also used to determine that the electrolytic cell has malfunctioned and to issue a real-time alarm through the alarm unit when the time for which the compensated temperature value is greater than or equal to the temperature set value reaches a threshold.

[0050] In some embodiments of this application, the control unit is further configured with a preset stirrer stirring rate matrix E, which is set as E(E1,E2,E3,E4), where E1 is the first preset stirrer stirring rate, E2 is the second preset stirrer stirring rate, E3 is the third preset stirrer stirring rate, and E4 is the fourth preset stirrer stirring rate, and E1 < E2 < E3 < E4.

[0051] The control unit is used to select the corresponding stirring speed of the stirrer as the stirring speed of the stirrer according to the relationship between S and the preset workpiece surface area matrix T0.

[0052] When S < T01, the first preset stirring speed E1 is selected as the stirring speed of the stirrer.

[0053] When T01≤S<T02, the second preset stirring speed E2 is selected as the stirring speed of the stirrer;

[0054] When T02≤S<T03, the third preset stirring speed E3 is selected as the stirring speed of the stirrer;

[0055] When T03≤S<T04, the fourth preset stirring speed E4 is selected as the stirring speed of the stirrer.

[0056] In some embodiments of this application, the monitoring unit is also used to monitor the energizing time W of the electrolytic cell in real time;

[0057] The control unit is also configured with a preset power-on duration matrix O0 and a preset stirrer stirring speed correction coefficient matrix F. For the preset stirrer stirring speed correction coefficient matrix F, F(F1,F2,F3,F4) is set, where F1 is the first preset stirrer stirring speed correction coefficient, F2 is the second preset stirrer stirring speed correction coefficient, F3 is the third preset stirrer stirring speed correction coefficient, and F4 is the fourth preset stirrer stirring speed correction coefficient, and 1 < F1 < F2 < F3 < F4 < 1.5;

[0058] For the preset power-on duration matrix O0, set O0(O01,O02,O03,O04), where O01 is the first preset power-on duration, O02 is the second preset power-on duration, O03 is the third preset power-on duration, O04 is the fourth preset power-on duration, and O01 < O02 < O03 < O04.

[0059] The control unit is also used to select the corresponding stirrer stirring rate correction coefficient according to the relationship between W and the preset power-on duration matrix O0, so as to correct the stirring rate of each preset stirrer.

[0060] When W < O01, the fourth preset stirrer stirring rate correction coefficient F4 is selected to correct the first preset stirrer stirring rate E1. The corrected stirrer stirring rate is E1*F4.

[0061] When O01≤W<O02, the third preset stirrer stirring rate correction coefficient F3 is selected to correct the second preset stirrer stirring rate E2. The corrected stirrer stirring rate is E2*F3.

[0062] When O02≤W<O03, the second preset stirrer stirring rate correction coefficient F2 is selected to correct the third preset stirrer stirring rate E3. The corrected stirrer stirring rate is E3*F2.

[0063] When O03≤W<O04, the first preset stirrer stirring rate correction coefficient F1 is selected to correct the fourth preset stirrer stirring rate E4, and the corrected stirrer stirring rate is E4*F1.

[0064] This invention provides an online monitoring system for electrolytic coloring, which has the following advantages compared with the prior art:

[0065] This invention uses a monitoring unit to detect the surface area of ​​the workpiece being processed and the parameters of the electrolyte in real time. The control unit controls the output current of the power module based on the surface area of ​​the workpiece and corrects the output current of the power module based on the temperature of the electrolyte. This establishes a real-time monitoring system for the production process, which improves the accuracy of the output current in workpiece processing. This ensures that the workpiece is fully processed, improves the quality of the finished product, and avoids some waste of power resources. This invention has the advantages of energy saving, high efficiency, and accuracy. Attached Figure Description

[0066] Figure 1 This is a functional block diagram of the online monitoring system for electrolytic coloring in an embodiment of the present invention. Detailed Implementation

[0067] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0068] In the description of this application, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0069] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0070] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the communication between the inner sides of two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0071] In existing technologies, the electrolytic coloring process of metals lacks precise control. Since there are many reasons for defects in the finished product, including the influence of impurities in the electrolyte solution and multiple influencing factors such as pH value, it is necessary to effectively monitor each stage of the electrolysis process in real time. Current methods rely on testing the finished product after processing, and there is no technical solution for real-time monitoring during the production process. This can lead to defects in the finished product, resulting in waste of raw materials and increased costs.

[0072] Therefore, the present invention provides an online monitoring system for electrolytic coloring. By dynamically and in real-time monitoring the process of metal electrolytic coloring, the system fully ensures the production quality of the electrolyte and the workpiece. Furthermore, by monitoring relevant parameters during the production process and automatically adjusting them, the system further prevents local defects in the finished workpiece and effectively improves the processing quality.

[0073] See Figure 1 As shown, the disclosed embodiment of the present invention provides an online monitoring system for electrolytic coloring, including: a power calculation module, a power supply module, an electrolytic cell, a stirrer, a heat exchanger, and a cooling device. The power calculation module is connected to the power supply module, the power supply module is connected to the electrolytic cell, the electrolytic cell is connected to the heat exchanger, the heat exchanger is connected to the cooling device, an electrolyte is provided in the electrolytic cell, and the stirrer is disposed in the electrolytic cell.

[0074] Also includes:

[0075] The monitoring unit is used to detect the surface area S of the workpiece being processed and the parameter information of the electrolyte in real time.

[0076] The control unit is used to control the output current of the power module according to the surface area S of the workpiece.

[0077] In one specific embodiment of this application, the control unit is configured with a preset workpiece surface area matrix T0 and a preset power module output current matrix A. For the preset power module output current matrix A, A(A1,A2,A3,A4) is set, where A1 is the first preset power module output current, A2 is the second preset power module output current, A3 is the third preset power module output current, and A4 is the fourth preset power module output current, and A1 < A2 < A3 < A4.

[0078] For a preset workpiece surface area matrix T0, set T0(T01,T02,T03,T04), where T01 is the first preset workpiece surface area, T02 is the second preset workpiece surface area, T03 is the third preset workpiece surface area, T04 is the fourth preset workpiece surface area, and T01 < T02 < T03 < T04.

[0079] The control unit is used to select the corresponding power module output current as the control power module output current based on the relationship between S and the preset workpiece surface area matrix T0.

[0080] When S < T01, the first preset power module output current A1 is selected as the output current of the control power module.

[0081] When T01≤S<T02, the output current A2 of the second preset power module is selected as the output current of the control power module;

[0082] When T02≤S<T03, the output current A3 of the third preset power supply module is selected as the output current of the control power supply module.

[0083] When T03≤S<T04, the output current A4 of the fourth preset power supply module is selected as the output current of the control power supply module.

[0084] Understandably, during anodizing, when the current is too high, the temperature rises at the localized current concentration points, causing the oxide film to thicken, turn white, and become powdery. Furthermore, the oxide film thins around the burned areas. This is mainly due to the excessively high localized current density caused by the proximity of the metal material to the counter electrode, insufficient stirring capacity, and uneven temperature distribution resulting from uneven stirring. When the current is too low, the workpiece surface cannot be effectively processed. Therefore, rationally controlling the output current according to the different surface areas of the workpiece to be processed can improve the processing quality of the workpiece.

[0085] In one specific embodiment of this application, the parameter information of the electrolyte includes the temperature K1 at the lowest liquid level and the temperature K2 at the highest liquid level.

[0086] The control unit also has a preset average electrolyte temperature matrix R0 and a preset power module output current correction coefficient matrix B. For the preset power module output current correction coefficient matrix B, B(B1,B2,B3,B4) is set, where B1 is the first preset power module output current correction coefficient, B2 is the second preset power module output current correction coefficient, B3 is the third preset power module output current correction coefficient, and B4 is the fourth preset power module output current correction coefficient, and 1 < B1 < B2 < B3 < B4 < 1.5;

[0087] For the preset electrolyte average temperature matrix R0, set R0(R01,R02,R03,R04), where R01 is the first preset electrolyte average temperature, R02 is the second preset electrolyte average temperature, R03 is the third preset electrolyte average temperature, and R04 is the fourth preset electrolyte average temperature, and R01 < R02 < R03 < R04.

[0088] The control unit is also used to select the corresponding power module output current correction coefficient according to the relationship between K1 and K2 and the preset electrolyte average temperature matrix R0 to correct the output current of each preset power module.

[0089] When (K1+K2) / 2<R01, the fourth preset power module output current correction coefficient B4 is selected to correct the first preset power module output current A1. The corrected power module output current is A1*B4.

[0090] When R01≤(K1+K2) / 2<R02, the third preset power module output current correction coefficient B3 is selected to correct the second preset power module output current A2. The corrected power module output current is A2*B3.

[0091] When R02≤(K1+K2) / 2<R03, the second preset power module output current correction coefficient B2 is selected to correct the third preset power module output current A3. The corrected power module output current is A3*B2.

[0092] When R03≤(K1+K2) / 2<R04, the first preset power module output current correction coefficient B1 is selected to correct the fourth preset power module output current A4. The corrected power module output current is A4*B1.

[0093] Understandably, the electrolyte temperature has a significant impact on the quality of the oxide film. When the temperature rises, the dissolution rate of the film increases, and the film thickness decreases. When the temperature is between 22 and 30°C, the resulting film is soft and has good adsorption capacity, but its wear resistance is quite poor. When the temperature is above 30°C, the film becomes loose and uneven, sometimes even discontinuous, and has low hardness, thus losing its usability. When the temperature is between 10 and 20°C, the generated oxide film is porous, has strong adsorption capacity, and is elastic, making it suitable for dyeing, but the film has low hardness and poor wear resistance. When the temperature is below 10°C, the oxide film thickness increases, the hardness is high, and the wear resistance is good, but the porosity is low. Furthermore, as the current flows, it also affects the temperature of the electrolyte solution. Therefore, it is necessary to dynamically adjust and control the output current according to the temperature at different points in the electrolytic cell.

[0094] In one specific embodiment of this application, the power module adopts a soft-start method when supplying power;

[0095] The control unit also has a preset voltage rise time matrix Y0, which is set as Y0(Y01,Y02,Y03,Y04), where Y01 is the first preset voltage rise time, Y02 is the second preset voltage rise time, Y03 is the third preset voltage rise time, and Y04 is the fourth preset voltage rise time, and 10s < Y01 < Y02 < Y03 < Y04 < 15s;

[0096] The control unit is also used to select the corresponding voltage rise time as the boost time for soft start of the power module based on the corrected output current of each power module.

[0097] When the corrected power module output current is A1*B4, the fourth preset voltage rise time Y04 is selected as the boost time for the power module soft start.

[0098] When the corrected power module output current is A2*B3, the third preset voltage rise time Y03 is selected as the boost time for the power module soft start.

[0099] When the corrected power module output current is A3*B2, the second preset voltage rise time Y02 is selected as the boost time for the power module soft start.

[0100] When the corrected power module output current is A4*B1, the first preset voltage rise time Y01 is selected as the boost time for the power module soft start.

[0101] Understandably, soft starters have the following advantages: low starting current, producing only a small starting current regardless of whether it is a large load or a capacitive load, improving the lifespan of the power supply, better ensuring the stability of product quality, and having no high requirements for input voltage, allowing the circuit to work normally even when the input voltage is high.

[0102] In one specific embodiment of this application, the monitoring unit is further configured to monitor the oxidation time in real time and calculate the surface oxide film thickness d of the workpiece based on the oxidation time; wherein, the surface oxide film thickness d of the workpiece is calculated using the following formula:

[0103] d = K * (I / s) * t;

[0104] In the formula, d is the thickness of the surface oxide film, K is a coefficient, which is taken as 0.3, I is the output current of the power module, s is the surface area of ​​the workpiece, and t is the oxidation time;

[0105] The control unit is also used to determine whether the workpiece is qualified for electrolytic coloring based on the comparison between the workpiece surface oxide film thickness d and the preset standard workpiece surface oxide film thickness value D.

[0106] When d=D, the workpiece is deemed to be qualified for electrolytic coloring.

[0107] When d < D or d > D, the workpiece is determined to be defective due to electrolytic coloring.

[0108] In one specific embodiment of this application, the control unit is provided with an alarm unit, and the control unit is also used to issue a real-time alarm through the alarm unit when it is determined that the electrolytic coloring of the workpiece is unqualified.

[0109] In one specific embodiment of this application, the control unit is further configured to base its calculations on the average value Q of K1 and K2. t To determine whether the electrolytic cell has malfunctioned, the effective temperature sequence is obtained, where t is an integer ≥ 1;

[0110] The valid judgment value is set to Z in the control unit. a And the judgment thresholds X and Z a =Q a -Q a-1 ;

[0111] The control unit is also used to control Z a Compare with X, when Z a When Z ≥ X, a Excluded from the effective temperature series, and delete Z. a When Z a When <X, Z a The effective temperature series is included in the calculation. Let the effective temperature series be {Mb}, where b is a positive integer; where 1≤a≤t and a is an integer, and X>0.

[0112] In one specific embodiment of this application, the control unit is further configured to calculate a compensation parameter V, wherein V = (H j-1 -H j-2 ) / (H j -H j-1 ), H j ∈{Mb}, j≥3 and j is an integer;

[0113] When (H) j-1 -H j-2 ) > 0 and (H j -H j-1 When ) > 0, the compensated temperature value is g = H j -|V|;

[0114] When (H) j-1 -H j-2 ) > 0 and (H j -H j-1 When ) < 0, the compensated temperature value is g = H j +|V|;

[0115] When (H) j-1 -H j-2 ) < 0 and (H j -H j-1 When ) < 0, the compensated temperature value is g = H j +|V|;

[0116] When (H) j-1 -H j-2 ) < 0 and (H j -Hj-1 When ) > 0, the compensated temperature value is g = H j -|V|;

[0117] When (H) j-1 -H j-2 When ) = 0, the compensated temperature value is g = H j ;

[0118] When (H) j -H j-1 When ) = 0, the compensated temperature value is g = H j ;

[0119] The control unit is also used to determine that the electrolytic cell has malfunctioned and to issue a real-time alarm through the alarm unit when the time when the compensated temperature value is greater than or equal to the temperature set value reaches a threshold.

[0120] In one specific embodiment of this application, the control unit is further configured with a preset stirrer stirring rate matrix E, which is set as E(E1,E2,E3,E4), where E1 is the first preset stirrer stirring rate, E2 is the second preset stirrer stirring rate, E3 is the third preset stirrer stirring rate, and E4 is the fourth preset stirrer stirring rate, and E1 < E2 < E3 < E4.

[0121] The control unit is used to select the appropriate stirring rate of the agitator based on the relationship between S and the preset workpiece surface area matrix T0.

[0122] When S < T01, the first preset stirring speed E1 is selected as the stirring speed of the stirrer.

[0123] When T01≤S<T02, select the second preset mixer speed E2 as the mixer speed;

[0124] When T02≤S<T03, select the third preset mixer speed E3 as the mixer speed;

[0125] When T03≤S<T04, select the fourth preset mixer speed E4 as the mixer speed.

[0126] Understandably, thorough stirring can promote strong convection in the electrolyte, enhance the cooling effect, ensure the uniformity of solution temperature, and prevent the oxide film quality from deteriorating due to localized heating of the metal. Furthermore, different circuits need to be applied depending on the surface area of ​​different workpieces. For workpieces with large processing surface areas, the applied current will be increased. As the applied current increases, the stirring rate needs to be accelerated, thereby improving the quality of the oxide film.

[0127] In one specific embodiment of this application, the monitoring unit is further configured to monitor the energizing duration W of the electrolytic cell in real time;

[0128] The control unit also has a preset power-on duration matrix O0 and a preset stirrer stirring speed correction coefficient matrix F. For the preset stirrer stirring speed correction coefficient matrix F, F(F1,F2,F3,F4) is set, where F1 is the first preset stirrer stirring speed correction coefficient, F2 is the second preset stirrer stirring speed correction coefficient, F3 is the third preset stirrer stirring speed correction coefficient, and F4 is the fourth preset stirrer stirring speed correction coefficient, and 1 < F1 < F2 < F3 < F4 < 1.5;

[0129] For the preset power-on duration matrix O0, set O0(O01,O02,O03,O04), where O01 is the first preset power-on duration, O02 is the second preset power-on duration, O03 is the third preset power-on duration, and O04 is the fourth preset power-on duration, and O01 < O02 < O03 < O04.

[0130] The control unit is also used to select the corresponding stirrer stirring rate correction coefficient according to the relationship between W and the preset power-on duration matrix O0 to correct the stirring rate of each preset stirrer.

[0131] When W < O01, the fourth preset mixer speed correction coefficient F4 is selected to correct the first preset mixer speed E1. The corrected mixer speed is E1*F4.

[0132] When O01≤W<O02, the third preset mixer speed correction coefficient F3 is selected to correct the second preset mixer speed E2. The corrected mixer speed is E2*F3.

[0133] When O02≤W<O03, the second preset mixer speed correction coefficient F2 is selected to correct the third preset mixer speed E3. The corrected mixer speed is E3*F2.

[0134] When O03≤W<O04, the first preset mixer speed correction coefficient F1 is selected to correct the fourth preset mixer speed E4. The corrected mixer speed is E4*F1.

[0135] It is understandable that as the energizing time increases, the electrolyte solution will also heat up, which in turn affects the temperature of the metal. This can lead to a decrease in the quality of the oxide film due to localized heating of the metal. Therefore, it is necessary to reasonably adjust the stirring rate to reduce the impact of temperature on the oxide film and improve the quality of the finished product.

[0136] In summary, this invention establishes a real-time monitoring system for the production process by using a monitoring unit to detect the surface area of ​​the workpiece and the parameters of the electrolyte in real time. The control unit adjusts the output current of the power module based on the workpiece's surface area and corrects it based on the electrolyte temperature. This improves the accuracy of the output current in workpiece processing, ensuring thorough processing, improving finished product quality, and avoiding energy waste. Furthermore, this invention determines processing quality based on oxide film thickness and provides real-time alarms to determine workpiece qualification, changing the traditional manual inspection method and improving production efficiency through automated inspection. This invention offers advantages such as energy saving, high efficiency, and accuracy.

[0137] The above is only one embodiment of the present invention, but it cannot be used to limit the scope of the present invention. Any structural changes made based on the present invention, as long as they do not lose the essence of the present invention, should be considered to fall within the protection scope of the present invention and be subject to its restrictions.

[0138] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working process and related descriptions of the system described above can be found in the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0139] It should be noted that the system provided in the above embodiments is only illustrated by the division of the above functional modules. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the modules or steps in the embodiments of the present invention can be further decomposed or combined. For example, the modules in the above embodiments can be merged into one module, or further divided into multiple sub-modules to complete all or part of the functions described above. The names of the modules and steps involved in the embodiments of the present invention are only for distinguishing the various modules or steps and are not considered as an improper limitation of the present invention.

[0140] Those skilled in the art will recognize that the modules and method steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. The programs corresponding to the software modules and method steps can be placed in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. To clearly illustrate the interchangeability of electronic hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in electronic hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the invention.

[0141] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent in such process, method, article, or apparatus / device.

[0142] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will all fall within the scope of protection of the present invention.

[0143] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention.

Claims

1. An online monitoring system for electrolytic coloring, characterized in that, include: The system includes a power calculation module, a power supply module, an electrolytic cell, a stirrer, a heat exchanger, and a cooling device. The power calculation module is connected to the power supply module, the power supply module is connected to the electrolytic cell, the electrolytic cell is connected to the heat exchanger, the heat exchanger is connected to the cooling device, the electrolytic cell contains an electrolyte, and the stirrer is located inside the electrolytic cell. Also includes: A monitoring unit is used to detect the surface area S of the workpiece being processed and the parameter information of the electrolyte in real time. Control unit, the control unit being used to control the output current of the power module according to the surface area S of the workpiece; The control unit is configured with a preset workpiece surface area matrix T0 and a preset power module output current matrix A. For the preset power module output current matrix A, A(A1,A2,A3,A4) is set, where A1 is the first preset power module output current, A2 is the second preset power module output current, A3 is the third preset power module output current, and A4 is the fourth preset power module output current, and A1 < A2 < A3 < A4. For the preset workpiece surface area matrix T0, set T0(T01,T02,T03,T04), where T01 is the first preset workpiece surface area, T02 is the second preset workpiece surface area, T03 is the third preset workpiece surface area, T04 is the fourth preset workpiece surface area, and T01 < T02 < T03 < T04. The control unit is used to select the corresponding power module output current as the control power module output current according to the relationship between S and the preset workpiece surface area matrix T0. When S < T01, the first preset power module output current A1 is selected as the output current to control the power module. When T01≤S<T02, the second preset power module output current A2 is selected as the output current for controlling the power module; When T02≤S<T03, the output current A3 of the third preset power module is selected as the output current for controlling the power module. When T03≤S<T04, the output current A4 of the fourth preset power module is selected as the output current for controlling the power module. The parameter information of the electrolyte includes the temperature K1 at the lowest liquid level and the temperature K2 at the highest liquid level. The control unit is also equipped with a preset electrolyte average temperature matrix R0 and a preset power module output current correction coefficient matrix B. For the preset power module output current correction coefficient matrix B, B(B1,B2,B3,B4) is set, where B1 is the first preset power module output current correction coefficient, B2 is the second preset power module output current correction coefficient, B3 is the third preset power module output current correction coefficient, and B4 is the fourth preset power module output current correction coefficient, and 1 < B1 < B2 < B3 < B4 < 1.5; For the preset electrolyte average temperature matrix R0, set R0(R01,R02,R03,R04), where R01 is the first preset electrolyte average temperature, R02 is the second preset electrolyte average temperature, R03 is the third preset electrolyte average temperature, and R04 is the fourth preset electrolyte average temperature, and R01 < R02 < R03 < R04. The control unit is also used to select the corresponding power module output current correction coefficient according to the relationship between K1 and K2 and the preset electrolyte average temperature matrix R0, so as to correct the output current of each preset power module. When (K1+K2) / 2<R01, the fourth preset power module output current correction coefficient B4 is selected to correct the first preset power module output current A1. The corrected power module output current is A1*B4. When R01≤(K1+K2) / 2<R02, the third preset power module output current correction coefficient B3 is selected to correct the second preset power module output current A2. The corrected power module output current is A2*B3. When R02≤(K1+K2) / 2<R03, the second preset power module output current correction coefficient B2 is selected to correct the third preset power module output current A3. The corrected power module output current is A3*B2. When R03≤(K1+K2) / 2<R04, the first preset power module output current correction coefficient B1 is selected to correct the fourth preset power module output current A4. The corrected power module output current is A4*B1. The power module adopts a soft start method when it is powered on. The control unit also has a preset voltage rise time matrix Y0, which is set as Y0(Y01,Y02,Y03,Y04), where Y01 is the first preset voltage rise time, Y02 is the second preset voltage rise time, Y03 is the third preset voltage rise time, and Y04 is the fourth preset voltage rise time, and 10s < Y01 < Y02 < Y03 < Y04 < 15s; The control unit is also used to select the corresponding voltage rise time as the boost time for soft start of the power module based on the corrected output current of each power module. When the corrected power module output current is A1*B4, the fourth preset voltage rise time Y04 is selected as the boost time for the power module soft start. When the corrected power module output current is A2*B3, the third preset voltage rise time Y03 is selected as the boost time for the soft start of the power module. When the corrected power module output current is A3*B2, the second preset voltage rise time Y02 is selected as the boost time for the soft start of the power module. When the corrected power module output current is A4*B1, the first preset voltage rise time Y01 is selected as the boost time for the soft start of the power module.

2. The online monitoring system for electrolytic coloring according to claim 1, characterized in that, The monitoring unit is also used to monitor the oxidation time in real time and calculate the surface oxide film thickness d of the workpiece based on the oxidation time; wherein, the surface oxide film thickness d of the workpiece is calculated using the following formula: d = K * (I / s) * t; In the formula, d is the thickness of the surface oxide film, K is a coefficient, which is taken as 0.3, I is the output current of the power module, s is the surface area of ​​the workpiece, and t is the oxidation time; The control unit is also used to determine whether the workpiece is qualified for electrolytic coloring based on the comparison between the surface oxide film thickness d of the workpiece and the preset standard surface oxide film thickness value D of the workpiece. When d=D, the electrolytic coloring of the workpiece is deemed qualified; When d < D or d > D, the electrolytic coloring of the workpiece is determined to be unqualified.

3. The online monitoring system for electrolytic coloring according to claim 2, characterized in that, The control unit is equipped with an alarm unit, and the control unit is also used to issue a real-time alarm through the alarm unit when it is determined that the electrolytic coloring of the workpiece is unqualified.

4. The online monitoring system for electrolytic coloring according to claim 3, characterized in that, The control unit is also configured to base its calculations on the average value Q of K1 and K2. t To determine whether the electrolytic cell has malfunctioned, an effective temperature sequence is obtained, where t is an integer ≥ 1; The control unit is set to a valid judgment value of Z. a And the judgment thresholds X and Z a =Q a -Q a-1 ; The control unit is also used to control Z a Compare with X, when Z a When Z ≥ X, a The effective temperature series is not included, and Z is deleted. a When Z a When <X, Z a The effective temperature series is included in the calculation. The effective temperature series is set as {Mb}, where b is a positive integer; where 1≤a≤t and a is an integer, and X>0.

5. The online monitoring system for electrolytic coloring according to claim 4, characterized in that, The control unit is also used to calculate the compensation parameter V, where V = (H j-1 -H j-2 ) / (H j -H j-1 ), H j ∈{Mb}, j≥3 and j is an integer; When (H) j-1 -H j-2 ) > 0 and (H j -H j-1 When ) > 0, the compensated temperature value is g = H j -|V|; When (H) j-1 -H j-2 ) > 0 and (H j -H j-1 When ) < 0, the compensated temperature value is g = H j +|V|; When (H) j-1 -H j-2 ) < 0 and (H j -H j-1 When ) < 0, the compensated temperature value is g = H j +|V|; When (H) j-1 -H j-2 ) < 0 and (H j -H j-1 When ) > 0, the compensated temperature value is g = H j -|V|; When (H) j-1 -H j-2 When ) = 0, the compensated temperature value is g = H j ; When (H) j -H j-1 When ) = 0, the compensated temperature value is g = H j ; The control unit is also used to determine that the electrolytic cell has malfunctioned and to issue a real-time alarm through the alarm unit when the time for which the compensated temperature value is greater than or equal to the temperature set value reaches a threshold.

6. The online monitoring system for electrolytic coloring according to claim 1, characterized in that, The control unit is also configured with a preset mixer stirring rate matrix E, which is set as E(E1,E2,E3,E4), where E1 is the first preset mixer stirring rate, E2 is the second preset mixer stirring rate, E3 is the third preset mixer stirring rate, and E4 is the fourth preset mixer stirring rate, and E1 < E2 < E3 < E4. The control unit is used to select the corresponding stirring speed of the stirrer as the stirring speed of the stirrer according to the relationship between S and the preset workpiece surface area matrix T0. When S < T01, the first preset stirring speed E1 is selected as the stirring speed of the stirrer. When T01≤S<T02, the second preset stirring speed E2 is selected as the stirring speed of the stirrer; When T02≤S<T03, the third preset stirring speed E3 is selected as the stirring speed of the stirrer; When T03≤S<T04, the fourth preset stirring speed E4 is selected as the stirring speed of the stirrer.

7. The online monitoring system for electrolytic coloring according to claim 1, characterized in that, The monitoring unit is also used to monitor the energizing time W of the electrolytic cell in real time; The control unit is also configured with a preset power-on duration matrix O0 and a preset stirrer stirring speed correction coefficient matrix F. For the preset stirrer stirring speed correction coefficient matrix F, F(F1,F2,F3,F4) is set, where F1 is the first preset stirrer stirring speed correction coefficient, F2 is the second preset stirrer stirring speed correction coefficient, F3 is the third preset stirrer stirring speed correction coefficient, and F4 is the fourth preset stirrer stirring speed correction coefficient, and 1 < F1 < F2 < F3 < F4 < 1.5; For the preset power-on duration matrix O0, set O0(O01,O02,O03,O04), where O01 is the first preset power-on duration, O02 is the second preset power-on duration, O03 is the third preset power-on duration, O04 is the fourth preset power-on duration, and O01 < O02 < O03 < O04. The control unit is also used to select the corresponding stirrer stirring rate correction coefficient according to the relationship between W and the preset power-on duration matrix O0, so as to correct the stirring rate of each preset stirrer. When W < O01, the fourth preset stirrer stirring rate correction coefficient F4 is selected to correct the first preset stirrer stirring rate E1. The corrected stirrer stirring rate is E1*F4. When O01≤W<O02, the third preset stirrer stirring rate correction coefficient F3 is selected to correct the second preset stirrer stirring rate E2. The corrected stirrer stirring rate is E2*F3. When O02≤W<O03, the second preset stirrer stirring rate correction coefficient F2 is selected to correct the third preset stirrer stirring rate E3. The corrected stirrer stirring rate is E3*F2. When O03≤W<O04, the first preset stirrer stirring rate correction coefficient F1 is selected to correct the fourth preset stirrer stirring rate E4, and the corrected stirrer stirring rate is E4*F1.

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