Production process of a nanocrystalline core for a reactor

Abstract

The present invention relates to the technical field of coating processes, and specifically discloses a production process for a nanocrystalline core of a reactor, including: Step 1: During the coating process, the nanocrystalline soft magnetic material is detected to obtain detection data; Step 2: Based on the detection data of the nanocrystalline soft magnetic material, the coating effect is evaluated to generate a coating effect signal; Step 3: Analyze whether the abnormal surface sub-region before coating the nanocrystalline soft magnetic material will affect the coating process and generate a signal indicating the impact on the coating process; Step 4: Based on the signal indicating the impact on the coating process, the coating process is adjusted according to the abnormal surface sub-region before coating the nanocrystalline soft magnetic material; When the present invention detects an abnormal surface sub-region before coating, the coating analysis model is used to accurately calculate how to adjust the process parameters to avoid similar abnormalities after coating, which not only improves the accuracy and controllability of the coating process, but also significantly enhances the quality and stability of the coated nanocrystalline soft magnetic products.

Description

Technical Field

[0001] The present invention relates to the technical field of coating processes, and particularly to a production process for a nano-crystalline core of a reactor. Background Art

[0002] With the continuous development of power electronics technology, the requirements for magnetic core materials of electronic components such as power transformers and inductors are getting higher and higher. Traditional magnetic core materials have deficiencies in aspects such as magnetic induction intensity, permeability loss, and working temperature range, and it is difficult to meet the needs of high-performance electronic components. As a new type of high-performance electronic component material, nano-crystalline cores have advantages such as high saturation magnetic induction intensity, low permeability loss, wide temperature range operation, and high dimensional stability. Therefore, the research on its production process is of great significance; however, in the production process of nano-crystalline cores, the coating process of the curing agent has an important impact on the performance of the cores.

[0003] However, in the prior art, in the curing agent coating process, it is not possible to quickly detect the coating quality of nano-crystalline soft magnets with different shapes, sizes, and surface characteristics, nor can it accurately calculate the process parameters using a coating analysis model based on the abnormal surface sub-regions existing before coating to avoid similar abnormalities after coating. Summary of the Invention

[0004] The purpose of the present invention is to provide a production process for a nano-crystalline core of a reactor to solve the technical problems in the above background.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] The present invention provides a production process for a nano-crystalline core of a reactor, including the following steps: raw material preparation, rapid solidification preparation, heat treatment, and curing treatment. It is characterized in that in the curing treatment, the following steps are included:

[0007] Detect the nano-crystalline soft magnetic curing agent coating process during curing treatment to determine the coating process parameters. The specific method includes the following steps:

[0008] Step 1: During the coating process, detect the nano-crystalline soft magnet to obtain detection data;

[0009] Among them, the detection data includes: uniformity coefficient;

[0010] Step 2: Based on the detection data of the nano-crystalline soft magnet, evaluate the coating effect to generate a coating effect signal;

[0011] Step 3: Analyze whether the abnormal surface sub-regions of the nano-crystalline soft magnet before coating will affect the coating process and generate a signal indicating the influence on the coating process;

[0012] Among them, the signals affecting the coating process include: signals affecting the coating process and signals not affecting the coating process;

[0013] Step 4: Based on the signals affecting the coating process, and according to the abnormal surface sub-regions before nanocrystalline soft magnetic coating, regulate the coating process. The specific process is as follows:

[0014] Based on the signals affecting the coating process, establish a coating analysis model according to the abnormal surface sub-regions before coating, the abnormal surface sub-regions after coating, and the process parameters of the coating process;

[0015] In subsequent processes, obtain the abnormal surface sub-regions before coating of the nanocrystalline soft magnetic to be coated, and the absolute gray deviation value HP 待 , and based on the coating analysis model, obtain the newly calculated process parameter GY 新 , where HP 阈 is the absolute gray deviation threshold.

[0016] As a further solution of the present invention: The process of obtaining the uniformity coefficient is as follows:

[0017] After the nanocrystalline soft magnetic is coated with a curing agent, use a detection imaging device to obtain the gray histogram of the nanocrystalline soft magnetic, and based on the gray value, divide the surface of the nanocrystalline soft magnetic into multiple regions to obtain surface sub-regions; according to the gray values of all surface sub-regions, calculate the gray characterization average ratio and the gray uniformity value, and perform a summation calculation on the gray characterization average ratio and the gray uniformity value to output the uniformity coefficient.

[0018] As a further solution of the present invention: The process of obtaining the gray characterization average ratio is as follows:

[0019] Obtain the gray values and area ratios of all surface sub-regions, respectively perform a product calculation on the gray values and the area ratios of the corresponding surface sub-regions to output the gray characterization values of each surface sub-region; then perform an average calculation on the gray characterization values of all surface sub-regions to output the gray characterization average value; perform a ratio calculation on the gray characterization average value and the standard gray characterization average value to output the gray characterization average ratio;

[0020] Among them, the process of obtaining the area ratio is: obtain the area of the surface sub-region, perform a ratio calculation on the area of the surface sub-region and the total area of the surface of the nanocrystalline soft magnetic to output the area ratio.

[0021] As a further solution of the present invention: The process of obtaining the gray uniformity value is as follows:

[0022] Calculate the difference between the grayscale value and the standard grayscale value, output the grayscale deviation value, and mark the absolute value of the grayscale deviation value as the absolute grayscale deviation value. Compare the absolute grayscale deviation value with the absolute grayscale deviation threshold. When the absolute grayscale deviation value is greater than the absolute grayscale deviation threshold, generate a grayscale anomaly signal and mark the surface sub-region corresponding to the grayscale anomaly signal as the abnormal surface sub-region; obtain the grayscale difference and the total grayscale deviation parameter, and perform a product calculation on the grayscale difference and the total grayscale deviation parameter to output the grayscale uniformity value.

[0023] As a further solution of the present invention: The process of obtaining the grayscale difference is as follows:

[0024] Based on all surface sub-regions, calculate the difference between the maximum value and the minimum value of the grayscale deviation values in all surface sub-regions, and output the grayscale difference.

[0025] As a further solution of the present invention: The process of obtaining the total grayscale deviation parameter is as follows:

[0026] Based on the abnormal surface sub-regions, obtain the absolute grayscale deviation value of each surface sub-region, and perform a product calculation on the absolute grayscale deviation value and the area ratio of the corresponding surface sub-region respectively to output the grayscale deviation parameter of each abnormal surface sub-region; perform a summation calculation on all grayscale deviation parameters to output the total grayscale deviation parameter.

[0027] As a further solution of the present invention: The specific process of generating the coating effect signal is as follows:

[0028] The coating effect signal includes: a coating qualified signal and a coating unqualified signal;

[0029] Compare and analyze the uniformity coefficient with the uniformity coefficient threshold;

[0030] If the uniformity coefficient ≥ the uniformity coefficient threshold, generate a coating unqualified signal;

[0031] If the uniformity coefficient < the uniformity coefficient threshold, generate a coating qualified signal.

[0032] As a further solution of the present invention: The specific process of generating the signal affecting the coating process is as follows:

[0033] Before the nanocrystalline soft magnetic coating curing agent, obtain the abnormal surface sub-region before the nanocrystalline soft magnetic coating; analyze the abnormal surface sub-region before coating and the abnormal surface sub-region after coating, obtain the abnormal coincidence area ratio, and compare the abnormal coincidence area ratio with the abnormal coincidence area ratio threshold;

[0034] If the abnormal coincidence area ratio < the abnormal coincidence area, generate a signal that has no effect on the coating process;

[0035] If the abnormal coincidence area ratio ≥ the abnormal coincidence area, a signal affecting the coating process is generated.

[0036] As a further solution of the present invention: the process of obtaining the abnormal coincidence area ratio is as follows:

[0037] Based on the pre - coating abnormal surface sub - regions and post - coating abnormal surface sub - regions of the nanocrystalline soft magnetic, the obtained abnormal coincidence area; the abnormal coincidence area ratio YMB is obtained by calculation.

[0038] As a further solution of the present invention: the process of establishing the coating analysis model is as follows:

[0039] Based on multiple nanocrystalline soft magnets with unqualified coating, the modeling data of each unqualified nanocrystalline soft magnet with coating are obtained respectively; a preset coating analysis model is set; the modeling data of all unqualified nanocrystalline soft magnets with coating are substituted into the preset coating analysis model, and a1, a2 and a3 are calculated and obtained to obtain the coating analysis model.

[0040] Advantages of the present invention:

[0041] (1) By using the detection imaging device, the present invention obtains the gray - scale histogram of the nanocrystalline soft magnetic, calculates the uniformity coefficient, compares and analyzes the uniformity coefficient with the preset uniformity coefficient threshold, thereby evaluating the coating effect and generating a coating effect signal; ensuring the uniformity and consistency of the coating on the surface of the nanocrystalline soft magnetic, improving the reliability and stability of the product; adopting image - processing technology and gray - scale histogram analysis, thus can adapt to the coating quality detection of nanocrystalline soft magnets with different shapes, sizes and surface characteristics;

[0042] (2) By using the detection imaging device, the present invention respectively obtains the abnormal surface sub - regions of the nanocrystalline soft magnetic during and before and after the coating process, judges whether the pre - coating abnormal surface sub - regions affect the coating process by calculating the abnormal coincidence area ratio, and generates a corresponding signal affecting the coating process; through precise detection and evaluation steps, effectively guarantees the uniformity and consistency of the nanocrystalline soft magnetic coating, thereby significantly improving the overall performance and stability of the product. More importantly, through the identification and analysis of the pre - coating abnormal surface sub - regions, potential coating problems can be discovered in time, and corresponding treatment measures can be taken before coating, thus effectively avoiding the adverse effects of these problems on the coating process, and further improving the coating quality and the reliability of the product;

[0043] (3) The present invention deeply analyzes the abnormal surface sub-regions before and after coating, and combines the coating process parameters (such as coating pressure) to establish a coating analysis model; this model can predict the possible abnormalities after coating and adjust the coating process parameters accordingly; specifically, when an abnormal surface sub-region is detected before coating, the coating analysis model is used to accurately calculate how to adjust the process parameters to avoid similar abnormalities after coating; the present invention not only improves the accuracy and controllability of the coating process, but also significantly enhances the quality and stability of the nanocrystalline soft magnetic coating products, providing strong technical support for the production of high-quality nanocrystalline soft magnetic products. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The present invention will be further described below with reference to the accompanying drawings.

[0045] Figure 1 is the flowchart of Embodiment 2 of the present invention;

[0046] Figure 2 is the flowchart of Embodiment 3 of the present invention;

[0047] Figure 3 is the flowchart of Embodiment 4 of the present invention;

[0048] Figure 4 is the system block diagram of Embodiment 5 of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0049] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present invention.

[0050] Embodiment 1:

[0051] A production process of a nanocrystalline iron core for a reactor according to an embodiment of the present invention includes the following steps:

[0052] A1: Raw material preparation:

[0053] Select an iron-based alloy raw material and adjust the chemical composition of the raw material according to the required performance requirements of the nanocrystalline iron core.

[0054] A2: Rapid solidification preparation:

[0055] Heat the raw material to a molten state and prepare nanocrystalline soft magnetic through rapid solidification techniques (such as spray forming, melt spinning); during this process, by controlling the cooling rate and solidification conditions, the alloy forms nanoscale grains during solidification.

[0056] A3: Heat treatment:

[0057] The prepared nanocrystalline soft magnetic material is heat-treated to optimize its magnetic properties and structure;

[0058] A4: Curing treatment:

[0059] Prepare the diluted curing agent, coat the heat-treated nanocrystalline soft magnetic material, and perform drying treatment to obtain a nanocrystalline iron core.

[0060] Example 2:

[0061] Based on Example 1, please refer to Figure 1 As shown, a production process of a reactor nanocrystalline iron core according to an embodiment of the present invention further includes:

[0062] Step 1: During the curing agent coating process, detect the nanocrystalline soft magnetic material to obtain detection data;

[0063] Among them, the detection data includes: uniformity coefficient;

[0064] In some embodiments, after the nanocrystalline soft magnetic material is coated with the curing agent, use a detection imaging device to obtain the gray histogram of the nanocrystalline soft magnetic material, and based on the gray value, divide the surface of the nanocrystalline soft magnetic material into multiple regions to obtain surface sub-regions (using methods such as threshold segmentation or region growing in image processing technology, combined with the gray value in the gray histogram, divide the surface of the nanocrystalline soft magnetic material into multiple surface sub-regions so that the gray value in each surface sub-region is consistent. Here, the image processing technology is all prior art and will not be elaborated here); according to the gray values of all surface sub-regions, calculate the gray representation average ratio and gray uniformity value, perform a summation calculation on the gray representation average ratio and the gray uniformity value, and output the uniformity coefficient;

[0065] Exemplarily, the process of obtaining the gray representation average ratio is as follows:

[0066] Obtain the gray value and area ratio of all surface sub-regions, respectively perform a product calculation on the gray value and the area ratio of the corresponding surface sub-region, and output the gray representation value of each surface sub-region; then perform an average calculation on the gray representation values of all surface sub-regions to output the gray representation average value; perform a ratio calculation on the gray representation average value and the standard gray representation average value to output the gray representation average ratio;

[0067] Among them, the standard gray representation average value is: the gray representation average value preset in the process during the coating of the nanocrystalline soft magnetic material;

[0068] Further, the process of obtaining the area ratio is: obtain the area of the surface sub-region, perform a ratio calculation on the area of the surface sub-region and the total surface area of the nanocrystalline soft magnetic material, and output the area ratio;

[0069] The process of obtaining the gray-scale uniformity value is as follows:

[0070] Calculate the difference between the gray-scale value and the standard gray-scale value, output the gray-scale deviation value, and mark the absolute value of the gray-scale deviation value as the absolute gray-scale deviation value. Compare the absolute gray-scale deviation value with the absolute gray-scale deviation threshold. When the absolute gray-scale deviation value is greater than the absolute gray-scale deviation threshold, generate a gray-scale anomaly signal and mark the surface sub-region corresponding to the gray-scale anomaly signal as an abnormal surface sub-region; obtain the gray-scale difference and the total gray-scale deviation parameter, calculate the product of the gray-scale difference and the total gray-scale deviation parameter, and output the gray-scale uniformity value;

[0071] When the absolute gray-scale deviation value is greater than the absolute gray-scale deviation threshold, generate a gray-scale normal signal;

[0072] Among them, the standard gray-scale value is: the gray-scale value preset by the process during the coating process of nanocrystalline soft magnetic materials;

[0073] Furthermore, the process of obtaining the gray-scale difference is as follows:

[0074] Based on all surface sub-regions, calculate the difference between the maximum value and the minimum value of the gray-scale deviation values in all surface sub-regions, and output the gray-scale difference;

[0075] The process of obtaining the total gray-scale deviation parameter is as follows:

[0076] Based on the abnormal surface sub-regions, obtain the absolute gray-scale deviation value of each surface sub-region, calculate the product of the absolute gray-scale deviation value and the area ratio of the corresponding surface sub-region respectively, and output the gray-scale deviation parameter of each abnormal surface sub-region; sum up all the gray-scale deviation parameters and output the total gray-scale deviation parameter;

[0077] Step 2: Based on the detection data of nanocrystalline soft magnetic materials, evaluate the coating effect and generate a coating effect signal;

[0078] Among them, the coating effect signal includes: a coating qualified signal and a coating unqualified signal;

[0079] Compare and analyze the uniformity coefficient with the uniformity coefficient threshold;

[0080] If the uniformity coefficient ≥ the uniformity coefficient threshold, it indicates that the coating effect is not ideal, the surface coating of the nanocrystalline soft magnetic material is uneven, or the coating effect has a large gap with the ideal coating effect, and generate a coating unqualified signal;

[0081] If the uniformity coefficient < the uniformity coefficient threshold, it indicates that the coating effect is good, the surface coating of the nanocrystalline soft magnetic material is uniform, and the coating effect has a small gap with the ideal coating effect, and generate a coating qualified signal;

[0082] The technical solution of the embodiment of the present invention is mainly as follows: By detecting the imaging device, the gray histogram of the nanocrystalline soft magnetic is obtained, and the gray histogram reflects the gray distribution on the surface of the coating layer; Based on the gray values in the gray histogram, the surface of the coating layer is divided into multiple surface sub-regions, which helps to conduct a more detailed analysis of the coating layer; For each surface sub-region, calculate its gray characterization value, and then calculate the average gray characterization value of all surface sub-regions, compare the average gray characterization value with the standard average gray characterization value to obtain the average gray characterization ratio; At the same time, by calculating the absolute gray deviation value of each surface sub-region and comparing it with the absolute gray deviation threshold, mark the abnormal surface sub-regions and calculate the gray uniformity value; Finally, perform a summation calculation on the average gray characterization ratio and the gray uniformity value to obtain the uniformity coefficient; Compare the calculated uniformity coefficient with the preset uniformity coefficient threshold for comparative analysis, so as to evaluate the coating effect and generate a coating effect signal; Ensure the uniformity and consistency of the nanocrystalline soft magnetic surface coating, improve the reliability and stability of the product; Adopt image processing technology and gray histogram analysis, so as to adapt to the coating quality detection of nanocrystalline soft magnets with different shapes, sizes and surface characteristics;

[0083] Embodiment 3:

[0084] Based on Embodiment 1 and Embodiment 2, please refer to Figure 2 as shown, the production process of a reactor nanocrystalline iron core described in the embodiment of the present invention further includes:

[0085] Step 3: Analyze whether the abnormal surface sub-regions before the nanocrystalline soft magnetic coating will affect the coating process, and generate a signal indicating the impact on the coating process;

[0086] Among them, the signal indicating the impact on the coating process includes: a signal indicating an impact on the coating process and a signal indicating no impact on the coating process;

[0087] In some implementation schemes, before the nanocrystalline soft magnetic is coated with a curing agent, obtain the abnormal surface sub-regions before the nanocrystalline soft magnetic coating; Analyze the abnormal surface sub-regions before coating and the abnormal surface sub-regions after coating, obtain the abnormal coincidence area ratio, and compare the abnormal coincidence area ratio with the abnormal coincidence area ratio threshold;

[0088] If the abnormal coincidence area ratio < the abnormal coincidence area ratio threshold, it means that the coincidence degree of the analysis of the abnormal surface sub-regions before coating and the abnormal surface sub-regions after coating is low, and the abnormal surface sub-regions before the nanocrystalline soft magnetic coating will not affect the coating process, that is, generate a signal indicating no impact on the coating process;

[0089] If the abnormal overlapping area ratio ≥ the abnormal overlapping area ratio threshold, it indicates that the overlapping degree of the abnormal surface sub-region before coating and the abnormal surface sub-region after coating is high. The abnormal surface sub-region before nanocrystalline soft magnetic coating will affect the coating process, that is, a signal affecting the coating process is generated;

[0090] Exemplarily, the process of obtaining the abnormal overlapping area ratio is as follows:

[0091] Based on the abnormal surface sub-region before coating and the abnormal surface sub-region after coating of the nanocrystalline soft magnetic, the obtained abnormal overlapping area (the abnormal overlapping area is: the area of the overlapping region between the abnormal surface sub-region before coating and the abnormal surface sub-region after coating); Through the formula: The abnormal overlapping area ratio YMB is calculated, where YM is the abnormal overlapping area and YMZ is the total abnormal area (the total abnormal area is: the total area of the abnormal surface sub-region before coating and the abnormal surface sub-region after coating);

[0092] It should be explained that the method for obtaining the abnormal surface sub-region before coating is the same as the steps of the method for obtaining the abnormal surface sub-region after coating; In the method for obtaining the abnormal surface sub-region before coating and the method for obtaining the abnormal surface sub-region after coating, the numerical values of some standard values and thresholds are inconsistent; For example, in the method for obtaining the abnormal surface sub-region before coating, the standard gray-scale characterization mean is the gray-scale characterization mean of the nanocrystalline soft magnetic in the ideal state before the coating process of the nanocrystalline soft magnetic;

[0093] The technical solution of the embodiment of the present invention is mainly: By detecting the imaging device, the abnormal surface sub-regions of the nanocrystalline soft magnetic are obtained during and before and after the coating process. By calculating the abnormal overlapping area ratio, it is judged whether the abnormal surface sub-region before coating affects the coating process, and a corresponding signal affecting the coating process is generated; Through precise detection and evaluation steps, the uniformity and consistency of the nanocrystalline soft magnetic coating are effectively guaranteed, thereby significantly improving the overall performance and stability of the product. More importantly, through the identification and analysis of the abnormal surface sub-region before coating, potential coating problems can be timely discovered, and corresponding treatment measures can be taken before coating, thereby effectively avoiding the adverse effects of these problems on the coating process, and further improving the coating quality and the reliability of the product.

[0094] Embodiment 4:

[0095] Based on Embodiment 1, Embodiment 2 and Embodiment 3, please refer to Figure 3 As shown, the production process of a reactor nanocrystalline iron core described in the embodiment of the present invention further includes:

[0096] Step 4: Based on the signal affecting the coating process, the coating process is regulated according to the abnormal surface sub-region before the nanocrystalline soft magnetic coating;

[0097] In some embodiments, based on signals that affect the coating process, a coating analysis model is established according to the pre - coating abnormal surface sub - regions, the post - coating abnormal surface sub - regions, and the process parameters of the coating process, so as to facilitate adjusting the process parameters based on the coating analysis model and the pre - coating abnormal surface sub - regions in subsequent processes and prevent the generation of post - coating abnormal surface sub - regions;

[0098] Among them, the process parameters include but are not limited to: coating pressure;

[0099] Exemplarily, the process of establishing the coating analysis model is as follows:

[0100] Based on multiple non - compliant coated nanocrystalline soft magnets (non - compliant coated nanocrystalline soft magnets refer to the coated nanocrystalline soft magnets corresponding to the generation of non - compliant coating signals), the modeling data of each non - compliant coated nanocrystalline soft magnet is obtained respectively (the modeling data includes: the absolute grayscale deviation value of the pre - coating abnormal surface sub - region, the absolute grayscale deviation value of the post - coating abnormal surface sub - region, and the process parameters during coating of the abnormal surface sub - region); the preset coating analysis model is: HP 后 =a1×HP 前 +a2×GY + a3, where a1 and a2 are preset proportionality factors, a3 is a constant, HP 后 is the absolute grayscale deviation value of the post - coating abnormal surface sub - region, HP 前 is the absolute grayscale deviation value of the pre - coating abnormal surface sub - region, and GY is the process parameter during coating of the abnormal surface sub - region; substitute the modeling data of all non - compliant coated nanocrystalline soft magnets into the preset coating analysis model, calculate to obtain a1, a2, and a3, and obtain the coating analysis model HP 后 =a1×HP 前 +a2×GY + a3;

[0101] In subsequent processes, the specific method for adjusting the process parameters based on the coating analysis model and the pre - coating abnormal surface sub - region is as follows:

[0102] In subsequent processes, obtain the pre - coating abnormal surface sub - region of the nanocrystalline soft magnet to be coated, and the absolute grayscale deviation value HP 待 , and based on the coating analysis model, obtain the formula: GY 新 =(HP 阈 -a1×HP 待 -a3)÷a2, calculate to obtain the new process parameter GY 新 (the new process parameter GY 新 is the process parameter to prevent the generation of abnormal surface sub - regions on the nanocrystalline soft magnet to be coated after coating), where HP 阈 is the absolute grayscale deviation threshold;

[0103] The technical solution of the embodiment of the present invention is mainly as follows: during the coating process, by deeply analyzing the abnormal surface sub-regions before and after coating and combining coating process parameters (such as coating pressure), a coating analysis model is established; this model can predict the possible abnormalities after coating and adjust the coating process parameters accordingly; specifically, when an abnormal surface sub-region is detected before coating, the coating analysis model is used to accurately calculate how to adjust the process parameters to avoid similar abnormalities after coating; the present invention not only improves the accuracy and controllability of the coating process, but also significantly enhances the quality and stability of the nanocrystalline soft magnetic coating products, providing strong technical support for the production of high-quality nanocrystalline soft magnetic products.

[0104] Example Five:

[0105] Based on Example One, Example Two, Example Three, and Example Four, please refer to Figure 4 as shown, the nanocrystalline soft magnetic curing agent coating process after curing treatment is detected to determine the coating process parameters, which is executed by the coating control system. The coating control system includes:

[0106] Data acquisition module: used to detect the nanocrystalline soft magnetic during the coating process and obtain detection data;

[0107] Coating evaluation module: based on the detection data of the nanocrystalline soft magnetic, evaluate the coating effect and generate a coating effect signal;

[0108] Influence analysis module: used to analyze whether the abnormal surface sub-region before coating of the nanocrystalline soft magnetic will affect the coating process and generate a signal indicating the influence on the coating process;

[0109] Coating control module: based on the signal indicating the influence on the coating process, adjust the coating process according to the abnormal surface sub-region before coating of the nanocrystalline soft magnetic.

[0110] The setting of the magnitude of the above threshold is for the convenience of comparison. Regarding the magnitude of the threshold, it depends on the amount of sample data and the base quantity set by those skilled in the art for each set of sample data;

[0111] The above has described a detailed description of an embodiment of the present invention, but the content described is only a preferred embodiment of the present invention and cannot be considered as limiting the scope of implementation of the present invention. Any equivalent changes and improvements made within the scope of the application of the present invention shall still fall within the scope covered by the patent of the present invention.

Claims

1. A production process for a nanocrystalline core of a reactor, comprising: Raw material preparation, rapid solidification preparation, heat treatment, and curing treatment, characterized in that in the curing treatment, it includes: Detect the coating process of the nanocrystalline soft magnetic curing agent in the curing treatment to determine the coating process parameters. The specific method includes: S1. During the coating process, detect the nanocrystalline soft magnetic to obtain the uniformity coefficient: After coating the curing agent on the nanocrystalline soft magnetic, use the detection imaging device to obtain the gray level histogram of the nanocrystalline soft magnetic, and based on the gray level value, divide the surface of the nanocrystalline soft magnetic into multiple regions to obtain surface sub-regions; According to the gray level values of all surface sub-regions, calculate the gray level characterization average ratio and the gray level uniformity value, perform a summation calculation on the gray level characterization average ratio and the gray level uniformity value, and output the uniformity coefficient; The process of obtaining the gray level uniformity value is: Calculate the difference between the gray level value and the standard gray level value, output the gray level deviation value, and mark the absolute value of the gray level deviation value as the gray level absolute deviation value. Compare the gray level absolute deviation value with the gray level absolute deviation threshold. When the gray level absolute deviation value is greater than the gray level absolute deviation threshold, generate a gray level abnormal signal, and mark the surface sub-region corresponding to the gray level abnormal signal as an abnormal surface sub-region; Obtain the gray level difference and the total gray level deviation parameter, perform a product calculation on the gray level difference and the total gray level deviation parameter, and output the gray level uniformity value; The process of obtaining the gray level characterization average ratio is: Obtain the gray level value and the area ratio of all surface sub-regions, perform a product calculation on the gray level value and the area ratio of the corresponding surface sub-region respectively, and output the gray level characterization value of each surface sub-region; Then perform an average calculation on the gray level characterization values of all surface sub-regions, and output the gray level characterization average value; Perform a ratio calculation on the gray level characterization average value and the standard gray level characterization average value, and output the gray level characterization average ratio; S2. Based on the detection data of the nanocrystalline soft magnetic, evaluate the coating effect and generate a coating effect signal of a qualified coating signal or an unqualified coating signal: Compare and analyze the uniformity coefficient with the uniformity coefficient threshold; If the uniformity coefficient ≥ the uniformity coefficient threshold, generate an unqualified coating signal; S3. Analyze whether the abnormal surface sub-region before coating the nanocrystalline soft magnetic will affect the coating process and generate a signal affecting the coating process; Among them, the signal affecting the coating process includes: a signal having an impact on the coating process and a signal having no impact on the coating process; The specific process of generating the signal affecting the coating process is: Before coating the curing agent on the nanocrystalline soft magnetic, obtain the abnormal surface sub-region before coating the nanocrystalline soft magnetic; Analyze the abnormal surface sub-region before coating and the abnormal surface sub-region after coating to obtain the abnormal coincidence area ratio, and compare the abnormal coincidence area ratio with the abnormal coincidence area ratio threshold; The process of obtaining the abnormal coincidence area ratio is: Based on the abnormal surface sub-region before coating and the abnormal surface sub-region after coating of the nanocrystalline soft magnetic, obtain the abnormal coincidence area. The abnormal coincidence area is: the area of the overlapping region between the abnormal surface sub-region before coating and the abnormal surface sub-region after coating; Through the formula: Calculate the abnormal coincidence area ratio YMB, where YM is the abnormal coincidence area, YMZ is the total abnormal area, and the total abnormal area is the total value of the areas of the abnormal surface sub-regions before coating and the abnormal surface sub-regions after coating; If the abnormal coincidence area ratio ≥ the abnormal coincidence area ratio threshold, generate a signal that affects the coating process; S4. Based on the signal that affects the coating process, regulate the coating process according to the abnormal surface sub-regions before nanocrystalline soft magnetic coating. The specific process is as follows: Based on the signal that affects the coating process, establish a coating analysis model according to the abnormal surface sub-regions before coating, the abnormal surface sub-regions after coating, and the process parameters of the coating process; the process parameters include coating pressure; the establishment process of the coating analysis model is as follows: Based on multiple unqualified nanocrystalline soft magnets for coating, obtain the modeling data of each unqualified nanocrystalline soft magnet for coating respectively; the preset coating analysis model is: HP after = a1 × HP before + a2 × GY + a3, where a1 and a2 are preset proportional factors, a3 is a constant, HP after is the absolute deviation value of the gray level of the abnormal surface sub-region after coating, HP before is the absolute deviation value of the gray level of the abnormal surface sub-region before coating, and GY is the process parameter during coating of the abnormal surface sub-region; substitute the modeling data of all unqualified nanocrystalline soft magnets for coating into the preset coating analysis model, calculate to obtain a1, a2, and a3, and obtain the coating analysis model HP after = a1 × HP before + a2 × GY + a3.

2. The production process of a nanocrystalline core for a reactor according to claim 1, characterized in that, The process of obtaining the gray level difference value is as follows: Based on all surface sub-regions, calculate the difference between the maximum value and the minimum value of the gray level deviation values among all surface sub-regions, and output the gray level difference value; When the absolute deviation value of the gray level is greater than the gray level absolute deviation threshold, generate a gray level normal signal.

3. The production process of a reactor nanocrystalline core according to claim 2, characterized in that, The process of obtaining the total gray level deviation parameter is as follows: Based on the abnormal surface sub-regions, obtain the absolute deviation values of the gray levels of each surface sub-region, calculate the product of the absolute deviation value of the gray level and the area ratio of the corresponding surface sub-region respectively, and output the gray level deviation parameter of each abnormal surface sub-region; sum up all the gray level deviation parameters and output the total gray level deviation parameter.

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