A design method for tungsten wire printing in ceramic heating rods

Abstract

The present invention relates to the technical field of tungsten wire printing design, and in particular to a design method for tungsten wire printing in a ceramic heating rod. The present invention uses a three-dimensional profile scanning camera to collect images of the ceramic rod core, and can obtain an accurate three-dimensional model of a substrate. The tungsten wire layout design is based on the three-dimensional model of the substrate, so that the material and printing thickness of the heating tungsten wire and the temperature-controlling tungsten wire are the same. Compared with the method of printing the heating tungsten wire and the temperature-controlling tungsten wire separately, the unified printing can ensure that the layout of the heating tungsten wire and the temperature-controlling tungsten wire on the ceramic heating rod has a high degree of consistency, and the layout of the heating tungsten wire and the temperature-controlling tungsten wire can be completed simultaneously in one printing process, which greatly shortens the production cycle. Since only one printing operation is required, the number of printings and possible problems such as missing printing, reprinting, misalignment, etc. are reduced, which helps to improve the product yield, reduce the defective rate, improve the overall product quality, and reduce the manpower, material and time costs.

Description

Technical Field

[0001] The invention relates to the technical field of tungsten wire printing design, in particular to a design method for tungsten wire printing in a ceramic heating rod. Background Art

[0002] Among the many fields of heating technology today, ceramic heating rods have attracted much attention due to their outstanding performance. Traditional ceramic heating rods often face some technical difficulties during the manufacturing process, which limit the further improvement of their performance and the expansion of their application range.

[0003] On the one hand, how to achieve accurate tungsten wire layout for ceramic rod cores of different specifications and shapes has always been a challenge; traditional methods usually rely on experience and manual operation, and it is difficult to ensure the consistency and accuracy of each layout, which not only affects the heating effect and stability of the heating rod, but also increases production costs and scrap rates;

[0004] On the other hand, there are also some deficiencies in the design and layout of the heating tungsten filament and the temperature-controlling tungsten filament. The traditional method is difficult to achieve accurate division of the heating zone and the temperature-controlling zone, resulting in inaccurate temperature control and unable to meet some application scenarios with high temperature requirements. At the same time, the layout design of the heating tungsten filament and the temperature-controlling tungsten filament is usually set separately, resulting in different materials and thicknesses of the heating tungsten filament and the temperature-controlling tungsten filament, and unified printing cannot be achieved. Therefore, a design method for tungsten filament printing in ceramic heating rods is proposed to address the above problems. Summary of the invention

[0005] The purpose of the present invention is to provide a design method for tungsten wire printing in a ceramic heating rod to solve the problems raised in the above background technology.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A design method for tungsten wire printing in a ceramic heating rod comprises the following steps:

[0008] Step S1, ceramic rod information collection:

[0009] Use a 3D profile scanning camera to collect 3D profile images of the ceramic rod core, receive orders for ceramic heating rods, and determine the specifications of the ceramic heating rods;

[0010] Step S2, tungsten wire type information collection:

[0011] Collect tungsten wire raw material information, build a resistance model for each tungsten wire raw material according to the type and characteristics of the tungsten wire raw material, summarize the resistance model, and build a tungsten wire database;

[0012] Step S3: constructing a three-dimensional model of the substrate:

[0013] Constructing a three-dimensional model of the ceramic rod core according to the three-dimensional contour image, determining the coating area and shape of the substrate according to the three-dimensional model of the ceramic rod core, and constructing a three-dimensional model of the substrate according to the coating area and shape of the substrate;

[0014] Step S4: Tungsten wire layout design:

[0015] Divide the heating zone on the substrate three-dimensional model according to the specifications of the ceramic heating rod, determine the resistance of the heating tungsten wire, the resistance of the temperature-controlling tungsten wire, and the type of tungsten wire according to the specifications of the ceramic heating rod, determine the area of ​​the heating zone, determine the resistance ratio of the heating tungsten wire resistance to the temperature-controlling tungsten wire resistance, calculate the printing area of ​​the heating tungsten wire and the temperature-controlling tungsten wire according to the heating zone area and the resistance ratio, calculate the printing length of the heating tungsten wire and the temperature-controlling tungsten wire and the thickness and width of the cross-sectional area in combination with the resistance model corresponding to the tungsten wire type, the printing thickness of the heating tungsten wire and the temperature-controlling tungsten wire is the same, obtain the printing data of the heating tungsten wire and the temperature-controlling tungsten wire, plan the area of ​​the heating zone according to the resistance ratio, determine the heating wiring area and the temperature-controlling wiring area, and evenly arrange the heating tungsten wire and the temperature-controlling tungsten wire in the heating wiring area and the temperature-controlling wiring area according to the printing data of the heating tungsten wire and the temperature-controlling tungsten wire, respectively, to complete the tungsten wire layout design of the ceramic heating rod;

[0016] Step S5: Generate design drawing:

[0017] Design the layout of the ceramic heating rod tungsten wire according to the printing specifications of the corresponding substrate of the screen printing equipment, and generate the processing design drawing.

[0018] Preferably, the specifications of the ceramic heating rod include the size, rated power, operating temperature, rated voltage and current, usage requirements, and heating zone position of the ceramic heating rod.

[0019] Preferably, when determining the heating tungsten wire resistance, temperature control tungsten wire resistance, and tungsten wire type according to the specifications of the ceramic heating rod, determine the size, rated power, operating temperature, rated voltage and current, and use requirements of the ceramic heating rod, and use the power formula Determine the resistance of the heating tungsten wire, where P is the rated power, U is the rated voltage, and R is the resistance of the heating tungsten wire; determine the resistance of the temperature-control tungsten wire according to the design requirements of the ceramic heating rod temperature control system; consult the tungsten wire database according to the use requirements of the ceramic heating rod, and determine the tungsten wire type in combination with the resistance of the heating tungsten wire and the resistance of the temperature-control tungsten wire.

[0020] Preferably, when constructing a three-dimensional model of the ceramic rod core based on the three-dimensional contour image, the three-dimensional contour image of the ceramic rod core is received, and the three-dimensional contour image is converted into point cloud data, each pixel point corresponds to a coordinate point in the three-dimensional space, and a filtering algorithm is used to denoise the point cloud data, and a surface reconstruction algorithm is used to generate a continuous surface model from the point cloud data, and the reconstructed surface is optimized to obtain the three-dimensional model of the ceramic rod core.

[0021] Preferably, when constructing the substrate three-dimensional model, the ceramic rod core three-dimensional model is received, the bottom circumference and length of the ceramic rod core three-dimensional model are extracted, a substrate rectangle is constructed according to the bottom circumference and length, and reserved connection and fixing areas are set on the substrate rectangle to obtain the substrate three-dimensional model.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows: by collecting images of the ceramic rod core with a three-dimensional profile scanning camera, an accurate three-dimensional model of the substrate can be obtained, which is convenient for subsequent design; by planning the area of ​​the heating area according to the resistance ratio, the heating wiring area and the temperature control wiring area are determined, so that the heating tungsten wire and the temperature control tungsten wire can play the best role in their respective areas; the entire tungsten wire layout design step has undergone rigorous calculation and planning, from the establishment of the resistance model to the determination of the printing data, and then to the actual wiring operation, each link fully considers the influence of various factors on the product performance; the tungsten wire layout design obtained through the tungsten wire layout design, The material and printing thickness of the heating tungsten wire and the temperature-controlling tungsten wire are the same. Compared with the method of printing the heating tungsten wire and the temperature-controlling tungsten wire separately, unified printing can ensure that the layout of the heating tungsten wire and the temperature-controlling tungsten wire on the ceramic heating rod is highly consistent, and the layout of the heating tungsten wire and the temperature-controlling tungsten wire can be completed simultaneously during one printing process, which greatly shortens the production cycle. Since only one printing operation is required, the number of printings and possible problems such as missing printing, reprinting, and misalignment are reduced, which helps to improve the product yield, reduce the defective rate, improve the overall product quality, reduce the use of production processes and equipment, and reduce manpower, material and time costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the overall process of a design method for tungsten wire printing in a ceramic heating rod of the present invention;

[0024] Figure 2 This is the design drawing of the tungsten wire printing process in the present invention;

[0025] Serial number marking: 1. substrate; 2. heating tungsten filament; 3. temperature control tungsten filament. DETAILED DESCRIPTION

[0026] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0027] In order to better understand the above technical solution, the above technical solution will be described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0028] Example:

[0029] See also Figure 1, this embodiment provides a technical solution:

[0030] A design method for tungsten wire printing in a ceramic heating rod comprises the following steps:

[0031] Step S1, ceramic rod information collection:

[0032] Use a 3D profile scanning camera to collect 3D profile images of the ceramic rod core, receive orders for ceramic heating rods, and determine the specifications of the ceramic heating rods; the specifications of the ceramic heating rods include the size, rated power, operating temperature, rated voltage and current, use requirements, and heating zone location of the ceramic heating rods;

[0033] Step S2, tungsten wire type information collection:

[0034] Collect tungsten wire raw material information, build a resistance model for each tungsten wire raw material according to the type and characteristics of the tungsten wire raw material, summarize the resistance model, and build a tungsten wire database;

[0035] Step S3: constructing a three-dimensional model of the substrate:

[0036] Constructing a three-dimensional model of the ceramic rod core according to the three-dimensional contour image, determining the coating area and shape of the substrate according to the three-dimensional model of the ceramic rod core, and constructing a three-dimensional model of the substrate according to the coating area and shape of the substrate;

[0037] When constructing a three-dimensional model of the ceramic rod core according to the three-dimensional contour image, the three-dimensional contour image of the ceramic rod core is received, and the three-dimensional contour image is converted into point cloud data, each pixel point corresponds to a coordinate point in the three-dimensional space, and a filtering algorithm is used to perform denoising on the point cloud data, and a surface reconstruction algorithm is used to generate a continuous surface model from the point cloud data, and the reconstructed surface is optimized to obtain the three-dimensional model of the ceramic rod core;

[0038] When constructing the substrate three-dimensional model, the ceramic rod core three-dimensional model is received, the bottom perimeter and length of the ceramic rod core three-dimensional model are extracted, a substrate rectangle is constructed according to the bottom perimeter and length, and a reserved connection and fixing area is set on the substrate rectangle to obtain the substrate three-dimensional model;

[0039] Step S4: Tungsten wire layout design:

[0040] Divide the heating zone on the substrate three-dimensional model according to the specifications of the ceramic heating rod, determine the resistance of the heating tungsten wire, the resistance of the temperature-controlling tungsten wire, and the type of tungsten wire according to the specifications of the ceramic heating rod, determine the area of ​​the heating zone, determine the resistance ratio of the heating tungsten wire resistance to the temperature-controlling tungsten wire resistance, calculate the printing area of ​​the heating tungsten wire and the temperature-controlling tungsten wire according to the heating zone area and the resistance ratio, calculate the printing length of the heating tungsten wire and the temperature-controlling tungsten wire and the thickness and width of the cross-sectional area in combination with the resistance model corresponding to the tungsten wire type, the printing thickness of the heating tungsten wire and the temperature-controlling tungsten wire is the same, obtain the printing data of the heating tungsten wire and the temperature-controlling tungsten wire, plan the area of ​​the heating zone according to the resistance ratio, determine the heating wiring area and the temperature-controlling wiring area, and evenly arrange the heating tungsten wire and the temperature-controlling tungsten wire in the heating wiring area and the temperature-controlling wiring area according to the printing data of the heating tungsten wire and the temperature-controlling tungsten wire, respectively, to complete the tungsten wire layout design of the ceramic heating rod;

[0041] Among them, when determining the heating tungsten wire resistance, temperature control tungsten wire resistance, and tungsten wire type according to the specifications of the ceramic heating rod, determine the size, rated power, operating temperature, rated voltage and current, and use requirements of the ceramic heating rod, and according to the power formula Determine the resistance of the heating tungsten wire, where P is the rated power, U is the rated voltage, and R is the resistance of the heating tungsten wire; determine the resistance of the temperature-control tungsten wire according to the design requirements of the ceramic heating rod temperature control system; consult the tungsten wire database according to the use requirements of the ceramic heating rod, and determine the type of tungsten wire in combination with the resistance of the heating tungsten wire and the resistance of the temperature-control tungsten wire;

[0042] Step S5: Generate design drawing:

[0043] Design the layout of the ceramic heating rod tungsten wire according to the printing specifications of the corresponding substrate of the screen printing equipment, and generate the processing design drawing.

[0044] In this embodiment, calculating the printing area of ​​the heating tungsten wire and the temperature control tungsten wire according to the heating area and the resistance ratio includes the following steps:

[0045] 1. Clarify known parameters

[0046] Determine the heating area: The heating area on the three-dimensional model of the ceramic heating rod substrate has been determined through the previous steps and is recorded as ;

[0047] Determine the resistance ratio: The resistance ratio of the heating tungsten wire resistance to the temperature control tungsten wire resistance is known, recorded as ,in, is the resistance of the heating tungsten wire, is the resistance value of the temperature-controlled tungsten wire;

[0048] 2. Calculate the total area corresponding to the total resistance

[0049] Assume the total resistance is According to the relationship between resistance and area (in, is the resistivity of the tungsten wire material, is the length of the tungsten wire, is the area of ​​the tungsten wire) the total area can be derived ;

[0050] The total area here is the sum of the total area of ​​the heating tungsten wire and the temperature-controlling tungsten wire;

[0051] 3. Allocate area according to resistance ratio

[0052] Assume that the printing area of ​​the heating tungsten wire is , the printing area of ​​the temperature-controlled tungsten wire is ;

[0053] Since the resistance ratio is known and (When length and resistivity are the same, resistance is inversely proportional to area);

[0054] Also because ;

[0055] Solve the above two equations together:

[0056] Depend on Available ;

[0057] Substitute it into In, get ;

[0058] Further simplified to ;

[0059] Thus, the printing area of ​​the heating tungsten wire can be calculated ;

[0060] According to Calculate the printing area of ​​the temperature-controlled tungsten wire: .

[0061] In this embodiment, the specific operation of calculating the printing length and the thickness and width of the cross-sectional area of ​​the heating tungsten filament and the temperature-controlling tungsten filament in combination with the resistance model corresponding to the tungsten filament type is as follows:

[0062] 1. Clarify the resistance model and known parameters

[0063] Resistance model: According to the law of resistance ,in, is the resistor, is the resistivity of the tungsten filament material (determined by the type of tungsten filament), is the length, is the cross-sectional area;

[0064] Known parameters:

[0065] The calculated printing area of ​​the heating tungsten wire and the temperature-controlled tungsten wire and ;

[0066] Assume that the resistance of the heating tungsten wire and the temperature-controlling tungsten wire is known and ;

[0067] It is known that the printing thickness of the heating tungsten wire and the temperature-controlling tungsten wire is the same, both set as T;

[0068] 2. Calculate the length

[0069] For heating tungsten wire:

[0070] From the resistance formula we can get ,in, ( is the width of the heating tungsten wire, is the length of the heating tungsten wire);

[0071] Will Substituting into ;

[0072] Since there are two unknowns and , needs to be solved in combination with other conditions;

[0073] For temperature controlled tungsten wire:

[0074] Similarly, ,in ;

[0075] Will Substituting into ;

[0076] 3. Determine the width and thickness

[0077] because Known, combine the length calculation formula with known area, resistance and other parameters to solve;

[0078] We can make an assumption about the value of a variable, such as the width of the heating tungsten wire. is a specific value, and then according to Find ;

[0079] Then the obtained Substitution Verification is performed, and if the conditions are met, the width and length of the heating tungsten wire are determined;

[0080] Similarly, perform similar operations on the temperature-controlled tungsten wire to determine its width and length.

[0081] See also Figure 2 In the processing design diagram obtained based on the above method, the heating tungsten wire 2 and the temperature controlling tungsten wire 3 are printed on the substrate 1.

[0082] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A design method for tungsten wire printing in a ceramic heating rod, characterized in that: The following steps are involved: Step S1, ceramic rod information collection: Use a 3D profile scanning camera to collect 3D profile images of the ceramic rod core, receive orders for ceramic heating rods, and determine the specifications of the ceramic heating rods; Step S2, tungsten wire type information collection: Collect tungsten wire raw material information, build a resistance model for each tungsten wire raw material according to the type and characteristics of the tungsten wire raw material, summarize the resistance model, and build a tungsten wire database; Step S3: constructing a three-dimensional model of the substrate: Constructing a three-dimensional model of the ceramic rod core according to the three-dimensional contour image, determining the coating area and shape of the substrate according to the three-dimensional model of the ceramic rod core, and constructing a three-dimensional model of the substrate according to the coating area and shape of the substrate; Step S4: Tungsten wire layout design: Divide the heating zone on the substrate three-dimensional model according to the specifications of the ceramic heating rod, determine the resistance of the heating tungsten wire, the resistance of the temperature-controlling tungsten wire, and the type of tungsten wire according to the specifications of the ceramic heating rod, determine the area of ​​the heating zone, determine the resistance ratio of the heating tungsten wire resistance to the temperature-controlling tungsten wire resistance, calculate the printing area of ​​the heating tungsten wire and the temperature-controlling tungsten wire according to the heating zone area and the resistance ratio, calculate the printing length of the heating tungsten wire and the temperature-controlling tungsten wire and the thickness and width of the cross-sectional area in combination with the resistance model corresponding to the tungsten wire type, the printing thickness of the heating tungsten wire and the temperature-controlling tungsten wire is the same, obtain the printing data of the heating tungsten wire and the temperature-controlling tungsten wire, plan the area of ​​the heating zone according to the resistance ratio, determine the heating wiring area and the temperature-controlling wiring area, and evenly arrange the heating tungsten wire and the temperature-controlling tungsten wire in the heating wiring area and the temperature-controlling wiring area according to the printing data of the heating tungsten wire and the temperature-controlling tungsten wire, respectively, to complete the tungsten wire layout design of the ceramic heating rod; Step S5: Generate design drawing: Design the layout of the ceramic heating rod tungsten wire according to the printing specifications of the corresponding substrate of the screen printing equipment, and generate the processing design drawing; The ceramic heating rod specifications include the size, rated power, operating temperature, rated voltage and current, usage requirements, and heating zone location of the ceramic heating rod; When determining the heating tungsten wire resistance, temperature control tungsten wire resistance, and tungsten wire type according to the ceramic heating rod specifications, determine the size, rated power, operating temperature, rated voltage and current, and usage requirements of the ceramic heating rod. Determine the resistance of the heating tungsten wire, where P is the rated power, U is the rated voltage, and R is the resistance of the heating tungsten wire; determine the resistance of the temperature-control tungsten wire according to the design requirements of the ceramic heating rod temperature control system; consult the tungsten wire database according to the use requirements of the ceramic heating rod, and determine the type of tungsten wire in combination with the resistance of the heating tungsten wire and the resistance of the temperature-control tungsten wire; When constructing the three-dimensional model of the ceramic rod core according to the three-dimensional contour image, the three-dimensional contour image of the ceramic rod core is received, the three-dimensional contour image is converted into point cloud data, each pixel point corresponds to a coordinate point in the three-dimensional space, a filtering algorithm is used to perform denoising on the point cloud data, a surface reconstruction algorithm is used to generate a continuous surface model from the point cloud data, and the reconstructed surface is optimized to obtain the three-dimensional model of the ceramic rod core; When constructing the substrate three-dimensional model, the ceramic rod core three-dimensional model is received, the bottom perimeter and length of the ceramic rod core three-dimensional model are extracted, a substrate rectangle is constructed according to the bottom perimeter and length, and a reserved connection and fixing area is set on the substrate rectangle to obtain the substrate three-dimensional model.

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