A real-time online monitoring system and method for ultrasonic heat treatment

Abstract

The invention discloses a real-time online monitoring system and method for ultrasonic heat treatment, and relates to the technical field of aluminum alloy heat treatment. The system comprises the following components: an ultrasonic sounding module, a heat treatment module, an acoustic signal receiving module and an analysis and control module. The invention constructs a real-time online monitoring system for ultrasonic heat treatment, which can capture and analyze the acoustic signals generated in the heat treatment process in real time, and judge the change of the material state in the heat treatment process through accurate analysis of the acoustic signals, thereby realizing real-time monitoring of the heat treatment process, and on this basis, establishing a quantitative coupling relationship between ultrasonic application parameters, heat treatment parameters and aluminum alloy performance, providing a scientific basis for process optimization, and realizing accurate control of the ultrasonic heat treatment process by continuously adjusting and optimizing these parameters, thereby significantly improving the performance and reliability of the aluminum alloy.

Description

Technical Field

[0001] The invention relates to the technical field of aluminum alloy heat treatment, and in particular to a real-time online monitoring system and method for ultrasonic heat treatment. Background Art

[0002] In the heat treatment process of aluminum alloys, the application of ultrasonic technology has received increasing attention. Ultrasonic treatment can affect the dissolution, diffusion and precipitation behavior of elements in aluminum alloys, and thus have a significant impact on the microstructure and macroscopic properties of the material. However, in practical applications, how to accurately control the ultrasonic application parameters and heat treatment parameters to achieve the optimization of aluminum alloy performance is still a problem that needs to be solved urgently.

[0003] At present, the heat treatment process of aluminum alloys usually relies on traditional temperature and time control methods. Although these methods can regulate the microstructure and properties of the material to a certain extent, they often lack real-time and accuracy. With the introduction of ultrasonic technology, people have begun to try to further regulate the heat treatment process through ultrasonic action in order to obtain better material properties.

[0004] However, there are many challenges in the ultrasonic heat treatment process. First, the interaction between ultrasonic application parameters (such as ultrasonic frequency, power and duration) and heat treatment parameters (such as heating temperature, holding time and cooling rate) is complex and difficult to accurately predict and control. Secondly, the export and analysis technology of acoustic signals is not yet mature. How to effectively capture, transmit and process the acoustic signals generated during ultrasonic heat treatment to obtain useful information is a technical difficulty currently faced. In addition, the connection and synchronization problems between the heat treatment equipment and the acoustic signal receiving equipment, as well as the construction of the intrinsic relationship between the changes in the heat treatment microstructure and the changes in the acoustic signal are also key issues that need to be solved urgently.

[0005] Therefore, developing a system and method that can monitor the changes in acoustic signals during ultrasonic heat treatment of aluminum alloys in real time and optimize the heat treatment process accordingly is of great significance for improving the performance and reliability of aluminum alloys. Summary of the invention

[0006] The purpose of the present invention is to make up for the shortcomings of the prior art and to provide a real-time online monitoring system and method for ultrasonic heat treatment, which can accurately judge the occurrence and degree of element dissolution, diffusion and precipitation behavior by receiving and analyzing the acoustic signals generated during the heat treatment process, providing a scientific basis for optimizing the ultrasonic heat treatment process. At the same time, a quantitative coupling relationship between ultrasonic application parameters, heat treatment parameters and aluminum alloy properties is established, thereby realizing the optimization control of the ultrasonic heat treatment process. In addition, by optimizing the design of the acoustic signal receiving module and the analysis and control module, the accuracy and real-time performance of the acoustic signal analysis are improved, providing strong support for the intelligent monitoring and control of the aluminum alloy heat treatment process.

[0007] In order to solve the above technical problems, the present invention provides the following technical solutions: On the one hand, a real-time online monitoring system for ultrasonic heat treatment, the system comprises the following components: an ultrasonic sounding module, a heat treatment module, an acoustic signal receiving module and an analysis and control module;

[0008] The ultrasonic sound module includes an ultrasonic sound generator and a related control circuit, which provides ultrasonic effect for heat treatment of aluminum alloy by generating ultrasonic signals;

[0009] The heat treatment module includes a heat treatment furnace and a temperature control system, wherein the heat treatment furnace provides a heat treatment environment, and the temperature control system accurately controls the heat treatment temperature to heat treat the aluminum alloy;

[0010] The acoustic signal receiving module includes an acoustic signal receiving probe, a signal amplifier and related signal transmission lines, which are used to receive the acoustic signals transmitted from the ultrasonic sounding module and the heat treatment module. The acoustic signal receiving probe receives the acoustic signal, and the signal amplifier amplifies the signal.

[0011] The analysis and control module is composed of a signal processor, a display and related data analysis software. The signal processor analyzes and processes the received acoustic signal, including filtering and feature extraction operations. The display is used to display the results of the analysis and processing, and monitor the heat treatment process of the aluminum alloy in real time. The data analysis software performs correlation analysis on the acoustic signal and the heat treatment parameters, and establishes a quantitative relationship between ultrasonic application, heat treatment parameters and aluminum alloy performance; wherein the correlation formula between the acoustic signal characteristics and the aluminum alloy performance is: Among them, P aluminum is the performance parameter of aluminum alloy, D0 is the basic performance parameter constant, which represents the basic performance value of aluminum alloy without any influence of acoustic signal characteristics, m is the total number of extracted acoustic signal characteristics, and D i is the weight coefficient of the i-th acoustic signal feature, reflecting the importance of this feature to the performance of aluminum alloy, G i is the frequency characteristic parameter of the ith sound signal, p is the exponential coefficient of the frequency characteristic parameter, H i is the amplitude characteristic parameter of the i-th sound signal, q is the exponential coefficient of the amplitude characteristic parameter, S i is the time characteristic parameter of the ith acoustic signal, r is the exponential coefficient of the time characteristic parameter, and the quantitative relationship between the acoustic signal characteristics and the performance of aluminum alloy is established by comprehensively considering the frequency, amplitude and time parameters of the acoustic signal and assigning different weights and exponential coefficients.

[0012] Furthermore, the ultrasonic sound module includes an ultrasonic sound generator and a related control circuit. The ultrasonic sound generator can generate an ultrasonic signal of a specific frequency and power, and has an adjustable frequency function to adapt to different aluminum alloy heat treatment requirements. The control circuit is used to accurately adjust the output parameters of the ultrasonic sound generator, including frequency and power. The ultrasonic sound generator output power adjustment formula is: Where P out is the actual output power of the ultrasonic generator, P max is the maximum output power of the ultrasonic generator, f current is the currently set ultrasonic frequency, f min is the minimum frequency of the ultrasonic sounder, f max is the maximum frequency of the ultrasonic sounder, K is the power adjustment coefficient, α is the temperature sensitivity coefficient, T is the current ambient temperature, and T0 is the reference temperature.

[0013] Furthermore, the ultrasonic sound generator module includes an ultrasonic sound generator and related control circuits, wherein the ultrasonic sound generator adopts a piezoelectric structure and utilizes the piezoelectric effect to efficiently convert electrical energy into mechanical energy to generate ultrasonic waves in a specific frequency range. In addition, the piezoelectric material of the ultrasonic sound generator is specially selected and processed, has a high electromechanical coupling coefficient, and can effectively convert electrical energy into ultrasonic energy.

[0014] Furthermore, the ultrasonic sound module includes an ultrasonic sound generator and related control circuits, wherein the control circuit is composed of a microprocessor, a drive circuit and a parameter adjustment circuit. The microprocessor is responsible for receiving external instructions and accurately controlling the operation of the drive circuit and the parameter adjustment circuit. The drive circuit uses high-performance electronic components to provide current and voltage to drive the ultrasonic sound generator. The parameter adjustment circuit accurately adjusts the output parameters of the ultrasonic sound generator according to different needs. At the same time, the control circuit also has fault detection and diagnosis functions, which can promptly detect and report faults of the ultrasonic sound generator and perform repairs and maintenance.

[0015] Furthermore, the heat treatment module is composed of a heat treatment furnace and a temperature control system. The heat treatment furnace has a space for accommodating aluminum alloy workpieces and has heating and heat preservation functions, and can provide a stable heat treatment environment. The temperature control system includes a temperature sensor and a controller. The temperature sensor monitors the temperature in the heat treatment furnace in real time. The controller adjusts the heating power of the heat treatment furnace according to the set temperature parameters to accurately control the heat treatment temperature. The temperature control formula of the heat treatment furnace is: Where T next is the temperature setting value of the heat treatment furnace at the next moment, T current is the current temperature of the heat treatment furnace, K p is the proportionality coefficient, E currrentis the temperature error at the current moment, that is, the difference between the target temperature and the actual temperature, K i is the integration coefficient, is the accumulated value of temperature error from the beginning to the current moment, K d is the differential coefficient, E last is the temperature error at the previous moment.

[0016] Furthermore, the acoustic signal receiving module includes an acoustic signal receiving probe, a signal amplifier and related signal transmission lines. The acoustic signal receiving probe receives the acoustic signal transmitted from the ultrasonic sounding module and the heat treatment module and converts it into an electrical signal. At the same time, the performance parameters of the acoustic signal receiving probe can work normally under the heat treatment environment. The signal amplifier amplifies the electrical signal output by the receiving probe to enhance the signal strength to meet the requirements of subsequent analysis and processing. The signal transmission line is used to transmit the amplified signal to the analysis control module. The signal amplifier gain adjustment formula is: Among them G amp is the actual gain of the signal amplifier, G0 is the initial gain, A is the gain adjustment amplitude coefficient, S input is the strength of the input sound signal, S ref is the reference signal strength, β is the temperature sensitivity coefficient, T is the current ambient temperature, and T0 is the reference temperature.

[0017] Furthermore, the acoustic signal receiving module includes an acoustic signal receiving probe, a signal amplifier and related signal transmission lines, wherein the acoustic signal receiving probe uses a high-sensitivity piezoelectric acoustic sensor, the frequency response range of the probe covers the operating frequency range of the ultrasonic generator, and the piezoelectric material of the acoustic signal receiving probe is specially processed and has high sensitivity and wide frequency response characteristics, and can accurately receive weak acoustic signals. At the same time, the shell of the probe is made of high-temperature resistant material, and can work stably for a long time in a heat treatment environment.

[0018] Furthermore, the signal transmission line adopts shielded cable and optical fiber as transmission media, the connection method adopts plug, socket and welding, and the signal transmission line is equipped with a signal isolation device to prevent external interference signals from affecting the acoustic signal.

[0019] On the other hand, a real-time online monitoring method for ultrasonic heat treatment is provided, wherein the specific steps of the method are:

[0020] Sample placement and ultrasonic heat treatment start-up: the aluminum alloy sample to be treated is placed in the heat treatment furnace of the heat treatment module, and the ultrasonic sounder of the ultrasonic sounding module is started to perform ultrasonic heat treatment on the aluminum alloy;

[0021] Acoustic signal reception and amplification: The acoustic signal receiving probe of the acoustic signal receiving module receives the acoustic signals transmitted from the ultrasonic sound generating module and the heat treatment module, and transmits these acoustic signals to the signal amplifier for amplification to meet the requirements of subsequent analysis;

[0022] Acoustic signal analysis and processing: The amplified acoustic signal is transmitted to the signal processor of the analysis and control module. The signal processor analyzes the acoustic signal in real time to determine whether the change of the acoustic signal is caused by heat treatment and analyzes the relationship between the acoustic signal and the heat treatment parameters.

[0023] Result display and real-time monitoring: The display of the analysis control module shows the analysis results in real time, including the changing trend of the acoustic signal, heat treatment parameters and quantitative relationship, so as to monitor the heat treatment process of the aluminum alloy in real time.

[0024] Compared with the prior art, the real-time online monitoring system and method for ultrasonic heat treatment has the following beneficial effects:

[0025] 1. The present invention constructs a real-time online monitoring system for ultrasonic heat treatment, which can capture and analyze the acoustic signals generated during the heat treatment process in real time. By accurately analyzing the acoustic signals, the changes in the material state during the heat treatment process can be judged, thereby realizing real-time monitoring of the heat treatment process. On this basis, a quantitative coupling relationship between ultrasonic application parameters, heat treatment parameters and aluminum alloy properties is established, which provides a scientific basis for process optimization. By continuously adjusting and optimizing these parameters, precise control of the ultrasonic heat treatment process can be achieved, thereby significantly improving the performance and reliability of the aluminum alloy.

[0026] 2. The present invention realizes the optimized control of the ultrasonic heat treatment process by establishing a quantitative coupling relationship between the ultrasonic application parameters, heat treatment parameters and the performance of the aluminum alloy, so that researchers and engineers can formulate and adjust the heat treatment process parameters more scientifically, thereby maximizing the potential of ultrasonic heat treatment, and by precisely controlling the ultrasonic application and heat treatment parameters, it helps to promote the optimization of the microstructure of the aluminum alloy, thereby improving the key performance indicators of the aluminum alloy such as the mechanical properties and corrosion resistance.

[0027] Other advantages, objectives and features of the present invention will be set forth in part in the following description and, in part, will be apparent to those skilled in the art based on an examination of the following or may be taught from the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention, and for ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0029] Figure 1 It is a schematic diagram of a real-time online monitoring system for ultrasonic heat treatment;

[0030] Figure 2 The present invention is a flow chart of a real-time online monitoring method for ultrasonic heat treatment. DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] Embodiment 1

[0033] This embodiment describes in detail a specific application of a real-time online monitoring system and method for ultrasonic heat treatment in the field of aluminum alloy powder metallurgy. By real-time monitoring of the heat treatment state and performance parameters of the casting, the parameters are adjusted in time according to the monitoring results to optimize the heat treatment process and ensure that the casting achieves the expected performance.

[0034] In the preparation stage, the various modules of the real-time online monitoring system for ultrasonic heat treatment are installed and connected. For the ultrasonic sound module, the ultrasonic sounder and related control circuits are carefully connected. When the ultrasonic sounder is working, its output power can be adjusted according to the actual situation. The formula is: Among them, P out Represents the actual output power of the ultrasonic generator, P max is the maximum output power of the ultrasonic generator, f current is the currently set ultrasonic frequency, f min is the minimum frequency of the ultrasonic sounder, f maxis the maximum frequency of the ultrasonic sounder, K is the power adjustment coefficient, α is the temperature sensitivity coefficient, T is the current ambient temperature, T0 is the reference temperature, and the output power of the ultrasonic sounder is accurately adjusted according to different frequency settings and ambient temperatures to meet the needs of heat treatment of aluminum alloy castings. Next, the heat treatment furnace is installed and connected to the temperature control system. The temperature control system includes a temperature sensor and a controller, wherein the temperature sensor can monitor the temperature in the heat treatment furnace in real time, and the controller adjusts the heating power of the heat treatment furnace according to the set temperature parameters. The temperature control formula of the heat treatment furnace is: Among them, T n ext is the temperature setting value of the heat treatment furnace at the next moment, T current is the current temperature of the heat treatment furnace, K p is the proportionality coefficient, E current is the temperature error at the current moment, that is, the difference between the target temperature and the actual temperature, K i is the integration coefficient, is the accumulated value of temperature error from the beginning to the current moment, K d is the differential coefficient, E last The temperature error at the last moment is calculated by accurately controlling the temperature of the heat treatment furnace to ensure that the aluminum alloy casting is heat treated in a stable temperature environment. Then, the acoustic signal receiving probe is installed, and the signal amplifier and signal transmission line are connected. The signal amplifier gain adjustment formula is: Among them, G amp is the actual gain of the signal amplifier, G0 is the initial gain, A is the gain adjustment amplitude coefficient, S input is the strength of the input sound signal, S refis the reference signal strength, β is the temperature sensitivity coefficient, T is the current ambient temperature, and T0 is the reference temperature. According to the input sound signal strength and ambient temperature, the gain of the signal amplifier is automatically adjusted to ensure that the output sound signal strength is moderate, which is convenient for subsequent processing. Finally, the signal processor, display and data analysis software of the analysis control module are connected to ensure that the sound signal can be analyzed and processed, and the analysis results are displayed. Then, according to the material, size and heat treatment process requirements of the aluminum alloy casting, the parameters of the ultrasonic sound module are set, and the frequency and power of the ultrasonic sounder are adjusted through the control circuit to meet the needs of heat treatment. In the process of setting parameters, previous empirical data and theoretical calculations can be referred to to determine the appropriate ultrasonic frequency and power range. At the same time, the specific conditions of the aluminum alloy casting, such as the shape, thickness, material and other factors of the casting, should be taken into account to ensure that the ultrasound can effectively act on the casting to achieve the purpose of optimizing the heat treatment effect. Subsequently, the parameters of the heat treatment module are set, and the target temperature and heating time of the heat treatment furnace are set through the temperature control system. When setting the target temperature, the temperature range should be determined according to the material and heat treatment process requirements of the aluminum alloy casting.

[0035] During the monitoring phase, the aluminum alloy castings are placed in the heat treatment furnace. When placing the castings, pay attention to the position and placement of the castings to ensure that the castings can be heated evenly. Use clamps or support devices to fix the castings in a suitable position in the heat treatment furnace to avoid movement or deformation during the heat treatment process. Start the ultrasonic sound module and the heat treatment module to generate ultrasonic signals of specific frequency and power to perform ultrasonic heat treatment on the aluminum alloy castings. At the same time, start the heating system of the heat treatment furnace to heat the aluminum alloy castings according to the set temperature parameters. During the startup process, pay close attention to the operating status of each module to ensure that the equipment is working properly. Then, the sound signal receiving module starts to receive sound signals, and the sound signal receiving probe receives the sound signals transmitted from the ultrasonic sound module and the heat treatment module. The signal is received by the acoustic signal processing module and converted into an electrical signal. In the process of receiving the acoustic signal, the position and angle of the probe are noted to ensure that the best acoustic signal can be received. Then the signal amplifier amplifies the electrical signal output by the receiving probe to enhance the signal strength. The signal amplifier automatically adjusts the gain according to the input acoustic signal strength and the ambient temperature to ensure that the output acoustic signal strength is moderate. The amplified signal is transmitted to the analysis and control module through the signal transmission line. Subsequently, the analysis and control module analyzes and processes the acoustic signal. The signal processor performs analysis and processing operations such as filtering and feature extraction on the received acoustic signal to extract the frequency characteristic parameters, amplitude characteristic parameters and time characteristic parameters of the acoustic signal. In the process of analysis and processing, the acoustic signal characteristics will be correlated with the aluminum alloy performance formula P. aluminum = Calculate, here, P aluminum is the performance parameter of aluminum alloy, Its meaning The mechanical properties (such as strength, hardness, toughness, etc.) and physical properties (such as density) of aluminum alloys areThe quantitative index of comprehensive performance of various aspects such as temperature, thermal expansion coefficient, etc. and chemical properties (such as corrosion resistance), D0 is the basic performance parameter constant, m is the total number of extracted acoustic signal features, D i is the weight coefficient of the i-th acoustic signal feature, G i is the frequency characteristic parameter of the ith sound signal, p is the exponential coefficient of the frequency characteristic parameter, H i is the amplitude characteristic parameter of the i-th sound signal, q is the exponential coefficient of the amplitude characteristic parameter, S i is the time characteristic parameter of the ith acoustic signal, r is the exponential coefficient of the time characteristic parameter, and the performance parameters of the aluminum alloy are calculated so as to understand the heat treatment state of the aluminum alloy casting in real time. Finally, the calculated performance parameters and the analysis results of the acoustic signal are displayed on the display so that the user can monitor the heat treatment process of the aluminum alloy casting in real time. At the same time, the data analysis software stores, queries and statistically analyzes the acoustic signals and heat treatment parameters. The data analysis software will store the acoustic signals and heat treatment parameters in real time for subsequent query and analysis, and can perform statistical analysis on the stored data to understand the acoustic signal change trend and performance change during the heat treatment of the aluminum alloy casting. Through the analysis of the data, the parameters in the formula for associating the acoustic signal characteristics with the aluminum alloy performance can be continuously optimized to improve the accuracy and reliability of the monitoring system.

[0036] In the adjustment stage, based on the monitoring results, determine whether the performance of the aluminum alloy castings meets the expected requirements. If the monitoring results show that the performance of the aluminum alloy castings does not meet the expected requirements, adjust the parameters of the ultrasonic sound module and the heat treatment module, that is, adjust the frequency and power of the ultrasonic sounder through the control circuit to change the effect of ultrasound on the aluminum alloy castings, and adjust the target temperature and heating time of the heat treatment furnace through the temperature control system to optimize the heat treatment process of the aluminum alloy castings. In the process of adjusting the parameters, pay close attention to the changes in the monitoring results to ensure that the adjusted parameters can effectively improve the performance of the aluminum alloy castings, and then continue to monitor the heat treatment process of the aluminum alloy castings. After adjusting the parameters, continue to monitor the heat treatment process of the aluminum alloy castings, and observe the changes in the sound signals and performance parameters in real time. Continuously adjust the parameters and monitor the process until the performance of the aluminum alloy castings meets the expected requirements.

[0037] At the end stage, when the heat treatment of the aluminum alloy casting is completed, turn off the ultrasonic sound module and the heat treatment module. When the performance of the aluminum alloy casting reaches the expected requirements, stop the ultrasonic sounder and turn off the heating system of the heat treatment furnace. Save the data during the monitoring process for subsequent analysis and research, maintain and service the monitoring system, inspect and maintain each module of the monitoring system to ensure the performance and reliability of the equipment, and regularly clean, calibrate and repair the equipment to extend its service life.

[0038] In summary, this embodiment monitors the heat treatment status and performance parameters of the casting in real time by accurately setting the parameters of the ultrasonic sound module and the heat treatment module, and adjusts the parameters in time according to the monitoring results to optimize the heat treatment process and ensure that the casting achieves the expected performance.

[0039] Embodiment 2

[0040] This embodiment describes in detail a specific application of a real-time online monitoring system and method for ultrasonic heat treatment in the field of aluminum alloy powder metallurgy. By introducing the present invention, the quality and performance of aluminum alloy products are improved, and the development of the aluminum alloy processing industry is promoted.

[0041] In the preparation stage, the installation and connection of each module of the ultrasonic heat treatment real-time online monitoring system are carried out. For the ultrasonic sound module, the ultrasonic sounder and the related control circuit are closely connected. During the operation of the ultrasonic sounder, its output power can be accurately adjusted according to a specific formula, which is: Among them, P out Represents the actual output power of the ultrasonic generator, P max is the maximum output power of the ultrasonic generator, f current is the currently set ultrasonic frequency, f min is the minimum frequency of the ultrasonic sounder, f max is the maximum frequency of the ultrasonic sounder, K is the power adjustment coefficient, α is the temperature sensitivity coefficient, T is the current ambient temperature, T0 is the reference temperature, and the output power of the ultrasonic sounder is carefully adjusted according to different frequency settings and ambient temperatures to meet the specific needs of heat treatment of aluminum alloy powder. Next, the heat treatment furnace is installed and connected to the temperature control system. The temperature control system includes a temperature sensor and a controller. The temperature sensor can monitor the temperature in the heat treatment furnace in real time, and the controller can accurately adjust the heating power of the heat treatment furnace according to the set temperature parameters. The temperature control formula of the heat treatment furnace is: Where T next is the temperature setting value of the heat treatment furnace at the next moment, T current is the current temperature of the heat treatment furnace, K p is the proportionality coefficient, E currrent is the temperature error at the current moment, that is, the difference between the target temperature and the actual temperature, K i is the integration coefficient, is the accumulated value of temperature error from the beginning to the current moment, K d is the differential coefficient, E last The temperature error at the last moment is calculated by accurately controlling the temperature of the heat treatment furnace to ensure that the aluminum alloy powder is heat treated in a stable temperature environment. Then, the acoustic signal receiving probe is installed, and the signal amplifier and signal transmission line are connected. The signal amplifier gain adjustment formula is: Among them G amp is the actual gain of the signal amplifier, G0 is the initial gain, A is the gain adjustment amplitude coefficient, S input is the strength of the input sound signal, S ref is the reference signal intensity, β is the temperature sensitivity coefficient, T is the current ambient temperature, and T0 is the reference temperature. According to the input acoustic signal intensity and ambient temperature, the gain of the signal amplifier is automatically adjusted to ensure that the output acoustic signal intensity is moderate for subsequent processing. Finally, the signal processor, display and data analysis software of the analysis control module are connected to ensure that the acoustic signal can be analyzed and processed, and the analysis results are displayed. Then, according to the characteristics of the aluminum alloy powder and the requirements of the heat treatment process, the parameters of the ultrasonic sound module are set. The frequency and power of the ultrasonic sounder are adjusted through the control circuit to meet the requirements of the heat treatment. In the process of setting the parameters, factors such as the particle size, shape and composition of the aluminum alloy powder should be fully considered. For example, if the powder particles are small, a higher ultrasonic frequency needs to be selected to ensure that the ultrasound can effectively act on the powder particles. At the same time, according to the requirements of the heat treatment process, the ultrasonic power should be determined to promote the solid-state tissue transformation. The previous experimental data and theoretical calculations can be referred to to determine the appropriate ultrasonic frequency and power range. Subsequently, the parameters of the heat treatment module are set, and the target temperature and heating time of the heat treatment furnace are set through the temperature control system. When setting the target temperature, the appropriate temperature range should be determined according to the requirements of the heat treatment process of the aluminum alloy powder.

[0042] In the monitoring stage, the Al-Si-Mg alloy powder is placed in a crucible, the ultrasonic sounder is started, ultrasound is applied below the melting point of the alloy, and the ultrasonic signal is introduced into the alloy powder through the resonance of the crucible. The changes in the powder particles are closely observed, and the acoustic signal receiving probe begins to receive the acoustic signal transmitted from the ultrasonic sounding module and the heat treatment module, and converts it into an electrical signal. In the process of receiving the acoustic signal, attention should be paid to the position and angle of the probe to ensure that the best acoustic signal can be received. Then, the signal amplifier amplifies the electrical signal output by the receiving probe to enhance the signal strength, and the signal amplifier will automatically adjust the gain according to the input acoustic signal strength and ambient temperature to ensure that the output acoustic signal strength is moderate. The amplified signal is transmitted to the analysis and control module through the signal transmission line. During the transmission process, a transmission medium such as a shielded cable or optical fiber is used to reduce the impact of external interference on the acoustic signal. Subsequently, the analysis and control module analyzes and processes the acoustic signal, and the signal processor performs analysis and processing operations such as filtering and feature extraction on the received acoustic signal to extract the frequency characteristic parameters, amplitude characteristic parameters and time characteristic parameters of the acoustic signal. In the analysis and processing process, the acoustic signal characteristics will be correlated with the aluminum alloy performance formula. Among them, P aluminum is the performance parameter of aluminum alloy, It covers the mechanical properties (such as strength, hardness, toughness, etc.), physical properties (such as density, thermal expansion coefficient, etc.) and Chemical properties (such as corrosion resistanceThe quantitative index of comprehensive performance in many aspects such as sound signal characteristics, D0 is the basic performance parameter constant, which represents the basic performance value of aluminum alloy without any influence of sound signal characteristics, m is the total number of extracted sound signal characteristics, and D i is the weight coefficient of the i-th acoustic signal feature, reflecting the importance of this feature to the performance of aluminum alloy, G i is the frequency characteristic parameter of the ith sound signal, p is the exponential coefficient of the frequency characteristic parameter, H i is the amplitude characteristic parameter of the i-th sound signal, q is the exponential coefficient of the amplitude characteristic parameter, S i is the time characteristic parameter of the ith acoustic signal, r is the exponential coefficient of the time characteristic parameter, and the performance parameters of the aluminum alloy are calculated so as to understand the heat treatment state of the aluminum alloy powder in real time. Finally, the calculated performance parameters and the analysis results of the acoustic signal are displayed on the display so that the user can monitor the heat treatment process of the aluminum alloy powder in real time. At the same time, the data analysis software stores, queries and statistically analyzes the acoustic signals and heat treatment parameters. The data analysis software will store the acoustic signals and heat treatment parameters in real time for subsequent query and analysis, and perform statistical analysis on the stored data to understand the acoustic signal change trend and performance change during the heat treatment of the aluminum alloy powder. For example, the frequency distribution curve and amplitude change curve of the acoustic signal can be drawn to observe the change law of the acoustic signal. Through the analysis of the data, the parameters in the formula for associating the acoustic signal characteristics with the aluminum alloy performance can be continuously optimized to improve the accuracy and reliability of the monitoring system.

[0043] In the adjustment stage, according to the monitoring results, it is judged whether the performance of the aluminum alloy powder meets the expected requirements. If the monitoring results show that the performance of the aluminum alloy powder does not meet the expected requirements, the parameters of the ultrasonic sound module and the heat treatment module are adjusted, that is, the frequency and power of the ultrasonic sounder are adjusted through the control circuit to change the effect of ultrasound on the aluminum alloy powder, and the target temperature and heating time of the heat treatment furnace are adjusted through the temperature control system to optimize the heat treatment process of the aluminum alloy powder. The sintering condition, organizational transformation and performance changes of the powder particles are observed, and the parameters are adjusted according to the actual situation. Then, the heat treatment process of the aluminum alloy powder is continued to be monitored. After adjusting the parameters, the heat treatment process of the aluminum alloy powder is continued to be monitored, and the changes in the sound signal and performance parameters are observed in real time. By continuously adjusting the parameters and monitoring the process, the performance of the aluminum alloy powder reaches the expected requirements. In this process, pay close attention to the changing trend of the sound signal, as well as the organizational transformation and performance changes of the aluminum alloy powder. If abnormal changes are found in the sound signal, analyze the reasons in time and take corresponding measures to make adjustments.

[0044] At the end stage, when the heat treatment of the aluminum alloy powder is completed, turn off the ultrasonic sound module and the heat treatment module. When the performance of the aluminum alloy powder reaches the expected requirements, stop the ultrasonic sounder, turn off the heating system of the heat treatment furnace, save the monitoring data, and save the data during the monitoring process for subsequent analysis and research. Maintain and maintain the monitoring system to ensure the performance and reliability of the equipment.

[0045] In summary, this embodiment adopts a unique power ultrasound application method through crucible resonance, applies ultrasound below the melting point of the alloy, monitors the solid-state structure transformation characteristics of the powder in real time, and continuously adjusts the parameters according to the monitoring results until the powder reaches the expected performance requirements. During the whole process, the various modules of the system cooperate with each other, and through functions such as signal reception, analysis and processing, and data storage, it provides strong support for optimizing the heat treatment process, greatly improving the efficiency and quality of heat treatment.

[0046] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A real-time online monitoring system for ultrasonic heat treatment, characterized in that: The system includes the following components: an ultrasonic sounding module, a heat treatment module, an acoustic signal receiving module and an analysis and control module; The ultrasonic sound module includes an ultrasonic sound generator and a related control circuit, which provides ultrasonic effect for heat treatment of aluminum alloy by generating ultrasonic signals; The heat treatment module includes a heat treatment furnace and a temperature control system, wherein the heat treatment furnace provides a heat treatment environment, and the temperature control system accurately controls the heat treatment temperature to heat treat the aluminum alloy; The acoustic signal receiving module includes an acoustic signal receiving probe, a signal amplifier and related signal transmission lines. The acoustic signal receiving probe receives the acoustic signal transmitted from the ultrasonic sounding module and the heat treatment module and converts it into an electrical signal. At the same time, the performance parameters of the acoustic signal receiving probe enable it to work normally under the heat treatment environment. The signal amplifier amplifies the electrical signal output by the acoustic signal receiving probe to enhance the signal strength to meet the requirements of subsequent analysis and processing. The signal transmission line is used to transmit the amplified electrical signal to the analysis control module. The signal amplifier gain adjustment formula is: Among them G amp is the actual gain of the signal amplifier, G0 is the initial gain, A is the gain adjustment amplitude coefficient, S input is the strength of the input sound signal, S ref is the reference signal strength, β is the temperature sensitivity coefficient, T is the current ambient temperature, and T0 is the reference temperature; The analysis and control module is composed of a signal processor, a display and related data analysis software. The signal processor analyzes and processes the received electrical signal, including filtering and feature extraction operations. The display is used to display the results of the analysis and processing, and monitor the heat treatment process of the aluminum alloy in real time. The data analysis software performs correlation analysis on the electrical signal and the heat treatment parameters, and establishes a quantitative relationship between ultrasonic application, heat treatment parameters and aluminum alloy performance; wherein the correlation formula between the acoustic signal characteristics and the aluminum alloy performance is: Among them, P aluminum is the performance parameter of aluminum alloy, D0 is the basic performance parameter constant, which represents the basic performance value of aluminum alloy without any influence of acoustic signal characteristics, m is the total number of extracted acoustic signal characteristics, and D i is the weight coefficient of the i-th acoustic signal feature, reflecting the importance of this feature to the performance of aluminum alloy, G i is the frequency characteristic parameter of the ith sound signal, p is the exponential coefficient of the frequency characteristic parameter, H i is the amplitude characteristic parameter of the i-th sound signal, q is the exponential coefficient of the amplitude characteristic parameter, S i is the time characteristic parameter of the i-th sound signal, and r is the exponential coefficient of the time characteristic parameter.

2. The real-time online monitoring system for ultrasonic heat treatment according to claim 1, characterized in that: The ultrasonic generator can generate ultrasonic signals of specific frequency and power, and has an adjustable frequency function to adapt to different aluminum alloy heat treatment requirements. The control circuit is used to accurately adjust the output parameters of the ultrasonic generator, including frequency and power. The ultrasonic generator output power adjustment formula is: Where P out is the actual output power of the ultrasonic generator, P max is the maximum output power of the ultrasonic generator, f current is the currently set ultrasonic frequency, f min is the minimum frequency of the ultrasonic sounder, f max is the maximum frequency of the ultrasonic sounder, K is the power adjustment coefficient, α is the temperature sensitivity coefficient, T is the current ambient temperature, and T0 is the reference temperature.

3. The real-time online monitoring system for ultrasonic heat treatment according to claim 2 is characterized in that: The ultrasonic sound generator adopts a piezoelectric structure and uses the piezoelectric effect to efficiently convert electrical energy into mechanical energy to generate ultrasonic waves in a specific frequency range. In addition, the piezoelectric material of the ultrasonic sound generator has been specially selected and processed, and has a high electromechanical coupling coefficient, which can effectively convert electrical energy into ultrasonic energy.

4. The real-time online monitoring system for ultrasonic heat treatment according to claim 2, characterized in that: The control circuit consists of a microprocessor, a drive circuit and a parameter adjustment circuit. The microprocessor is responsible for receiving external instructions and accurately controlling the operation of the drive circuit and the parameter adjustment circuit. The drive circuit uses high-performance electronic components to provide current and voltage to drive the ultrasonic sounder. The parameter adjustment circuit accurately adjusts the output parameters of the ultrasonic sounder according to different needs. At the same time, the control circuit also has fault detection and diagnosis functions, which can promptly detect and report faults of the ultrasonic sounder and perform repairs and maintenance.

5. The real-time online monitoring system for ultrasonic heat treatment according to claim 1, characterized in that: The heat treatment furnace has space to accommodate aluminum alloy workpieces, and has heating and heat preservation functions, which can provide a stable heat treatment environment. The temperature control system includes a temperature sensor and a controller. The temperature sensor monitors the temperature in the heat treatment furnace in real time. The controller adjusts the heating power of the heat treatment furnace according to the set temperature parameters to accurately control the heat treatment temperature. The temperature control formula of the heat treatment furnace is: Where T next is the temperature setting value of the heat treatment furnace at the next moment, T current is the current temperature of the heat treatment furnace, K p is the proportionality coefficient, E currrent is the temperature error at the current moment, that is, the difference between the target temperature and the actual temperature, K i is the integration coefficient, is the accumulated value of temperature error from the beginning to the current moment, K d is the differential coefficient, E last is the temperature error at the previous moment.

6. The real-time online monitoring system for ultrasonic heat treatment according to claim 1, characterized in that: The acoustic signal receiving probe uses a high-sensitivity piezoelectric acoustic sensor. The frequency response range of the probe covers the operating frequency range of the ultrasonic sounder. The piezoelectric material of the acoustic signal receiving probe has been specially processed and has high sensitivity and wide frequency response characteristics. It can accurately receive weak acoustic signals. At the same time, the probe shell is made of high-temperature resistant material and can work stably for a long time in a heat treatment environment.

7. The real-time online monitoring system for ultrasonic heat treatment according to claim 1, characterized in that: The signal transmission line uses shielded cables and optical fibers as transmission media, and the connection methods are plugs, sockets and welding. The signal transmission line is equipped with a signal isolation device to prevent external interference signals from affecting the acoustic signal.

8. A method for using the online monitoring system according to any one of claims 1 to 7, characterized in that: The specific steps of the method are: Sample placement and ultrasonic heat treatment start-up: the aluminum alloy sample to be treated is placed in the heat treatment furnace of the heat treatment module, and the ultrasonic sounder of the ultrasonic sounding module is started to perform ultrasonic heat treatment on the aluminum alloy; Acoustic signal reception and conversion: The acoustic signal receiving probe of the acoustic signal receiving module receives the acoustic signal transmitted from the ultrasonic sound generating module and the heat treatment module, and converts it into an electrical signal. The signal amplifier amplifies the electrical signal output by the acoustic signal receiving probe to enhance the signal strength so as to meet the requirements of subsequent analysis and processing; Acoustic signal analysis and processing: The amplified electrical signal is transmitted to the signal processor of the analysis and control module. The signal processor analyzes the electrical signal in real time to determine whether the change of the acoustic signal is caused by heat treatment and analyzes the relationship between the acoustic signal and the heat treatment parameters. Result display and real-time monitoring: The display of the analysis control module shows the analysis results in real time, including the changing trend of the acoustic signal, heat treatment parameters and quantitative relationship, so as to monitor the heat treatment process of the aluminum alloy in real time.

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