Dual-liquid flow control system for copper-clad aluminum material production

Abstract

The dual-liquid flow control system for copper-clad aluminum material production provided by the present invention relates to the technical field related to copper-clad aluminum material production, including: a data processing and analysis module, which is used to receive fluid parameter data for analysis and processing to obtain analysis and processing results; the analysis and processing results include flow parametric difference values, statistical indicators, adaptive adjustment signals and adaptive adjustment factors corresponding to the parameters in the fluid parameter data; a flow control execution module, which is used to receive the analysis and processing results, and perform corresponding control operations according to the adaptive adjustment signals in the analysis and processing results. The present invention realizes automated high-precision control of the flow of molten copper and molten aluminum, accurately calculates the initial valve opening and flow rate through the task acquisition module, and accurately adjusts the flow control execution module, combined with the detailed analysis of the fluid parameters by the data acquisition and processing module, to ensure that the copper layer is evenly coated on the aluminum core and tightly combined, which can effectively avoid the inclusion defect problem caused by the unstable flow of molten copper and molten aluminum.

Description

Technical Field

[0001] The invention relates to the technical field related to the production of copper-clad aluminum materials, and in particular to a dual-liquid flow control system used for the production of copper-clad aluminum materials. Background Art

[0002] With the rapid development of the electronics and power industries, the market demand for copper-clad aluminum materials is increasing due to the advantages of copper's excellent conductivity and aluminum's light weight and low cost. In the production process of copper-clad aluminum materials, the control of the flow rate and flow rate of copper liquid and aluminum liquid is extremely critical, which directly determines the uniformity of the copper layer on the aluminum core, the degree of bonding and the final performance of the product. The traditional method of relying on manual experience to control the valve to adjust the flow of copper and aluminum liquids has low precision and poor stability, and it is difficult to adapt to the requirements of modern large-scale and high-quality production. Affected by temperature and pressure fluctuations and changes in raw material properties, manual adjustments cannot be made in a timely and accurate manner, which can easily lead to uneven copper layer thickness, inclusion defects and even waste products. At the same time, production efficiency is low and production costs remain high. Therefore, it is urgent to develop an automated, high-precision dual-liquid flow control system.

[0003] In modern industrial production, copper-clad aluminum materials are widely used in many fields such as wires and cables, electronic components, etc. due to their unique performance advantages. The traditional way of regulating the flow of copper-aluminum liquid by manipulating valves based on manual experience has problems of low precision and poor stability, which makes it difficult to meet the needs of modern large-scale, high-quality production. Since the flow of copper-aluminum liquid is affected by temperature and pressure fluctuations and changes in the characteristics of raw materials, manual adjustments cannot be made in a timely and accurate manner, which can easily lead to uneven copper layer thickness, inclusion defects, and even waste products. At the same time, production efficiency is low and production costs remain high. Therefore, it is imperative to develop an automated, high-precision dual-liquid flow control system.

[0004] Therefore, it is necessary to provide a dual-liquid flow control system for the production of copper-clad aluminum materials to solve the above technical problems. Summary of the invention

[0005] The present invention provides a dual-liquid flow control system for the production of copper-clad aluminum materials, which solves the problems mentioned in the above background technology.

[0006] In order to solve the above technical problems, the present invention provides a dual-liquid flow control system for copper-clad aluminum material production, comprising:

[0007] A pipeline network, the pipeline network comprising a main pipeline and branch pipelines; the main pipeline and branch pipelines are used to transport molten copper and molten aluminum, and flow regulating devices are provided at key nodes of the pipeline network;

[0008] The task acquisition module is used to calculate the valve opening and flow rate corresponding to the copper liquid and the aluminum liquid in the initial state according to the preset production process requirements of the copper-clad aluminum material, and mark the valve opening and flow rate corresponding to the copper liquid and the aluminum liquid as the initial control signal;

[0009] A data acquisition module is used to collect fluid parameter data on the copper liquid and aluminum liquid pipelines during the production process of copper-clad aluminum materials, and transmit the fluid parameter data to the data processing and analysis module;

[0010] The data processing and analysis module is used to receive the fluid parameter data for analysis and processing to obtain the analysis and processing results; the analysis and processing results include the flow parameter difference value, statistical index, adaptive adjustment signaling and adaptive adjustment factors corresponding to the parameters in the fluid parameter data;

[0011] A flow control execution module, which is electrically connected to the flow regulating device; after receiving the initial control signal, it drives the valve actuator to adjust the valve to the corresponding opening position according to the valve opening value set in the initial control signal; it is also used to receive the analysis and processing results, and execute the corresponding control operation according to the adaptive adjustment signal in the analysis and processing results.

[0012] Preferably, the data acquisition module includes a number of piezoresistive pressure sensors, thermocouple temperature sensors, flow sensors, and flow velocity sensors arranged along the copper liquid and aluminum liquid pipelines; wherein the flow sensor can adopt a turbine flow sensor or an electromagnetic flow sensor, and the flow velocity sensor can adopt an ultrasonic flow velocity sensor or a Pitot tube flow velocity sensor.

[0013] Preferably, the fluid parameter data include flow-related parameters, flow velocity-related parameters, pressure-related parameters, temperature-related parameters and fluid physical property parameters in the copper liquid and aluminum liquid pipelines; flow-related parameters include flow rate and flow stability, flow velocity-related parameters include flow velocity and flow velocity uniformity, pressure-related parameters include static pressure and dynamic pressure, temperature-related parameters include fluid temperature and temperature uniformity, and fluid physical property parameters include viscosity and density.

[0014] As a preferred method, the fluid parameter data is received and analyzed, and the specific analysis is as follows:

[0015] Identify the preset production process requirements of the current copper-clad aluminum material, and extract the preset fluid parameter data corresponding to the copper liquid and aluminum liquid from the production process requirements;

[0016] The copper liquid and aluminum liquid pipelines are divided into several local pipelines; the fluid parameter data on the local pipelines corresponding to the copper liquid and the aluminum liquid are obtained; the difference between any parameter in the fluid parameter data on the local pipeline and the value of the corresponding parameter in the preset fluid parameter data is calculated to obtain the flow parameter difference value;

[0017] Set the monitoring time zone, obtain the flow parameter difference value of the fluid parameter data at any collection time in the monitoring time zone, and calculate the statistical indicators of the fluid parameter data in the monitoring time zone; the statistical indicators include the mean value, variance, maximum value, and minimum value;

[0018] The flow parameter difference value and the statistical index are weighted to obtain the local deviation value; the local deviation values ​​of all local pipelines are weighted to obtain the flow parameter influence value corresponding to the parameter in the fluid parameter data;

[0019] A flow parameter threshold is set, and the flow parameter impact value is compared with the flow parameter threshold. If the flow parameter impact value is greater than the flow parameter threshold, an adaptive adjustment signaling is generated; the adaptive adjustment signaling is used to trigger the analysis of the adaptive adjustment factor.

[0020] As a preferred method, the analysis of the adaptive adjustment factor is specifically as follows:

[0021] For the adaptive regulation signaling corresponding to the flow rate, the pipe diameter and pipe length are obtained, and the pipe diameter, pipe length and flow parameter influence value corresponding to the flow rate are weighted and calculated to obtain the adaptive regulation factor corresponding to the flow rate;

[0022] For the adaptive adjustment signaling corresponding to the flow velocity, the roughness of the pipeline and the fluid viscosity are obtained, and the roughness of the pipeline, the fluid viscosity and the flow parameter influence value corresponding to the flow velocity are weightedly calculated to obtain the adaptive adjustment factor corresponding to the flow velocity;

[0023] For the adaptive adjustment signaling corresponding to the pressure, the pipe diameter, pipe length, roughness, and fluid viscosity of the pipeline are obtained, and the pipe diameter, pipe length, roughness, fluid viscosity, and the flow parameter influence value corresponding to the pressure are weighted and calculated to obtain the adaptive adjustment factor corresponding to the pressure;

[0024] For the adaptive adjustment signaling corresponding to the temperature, the density, heat conduction and fluid viscosity of the liquid transported in the pipeline are obtained, and the density, heat conduction, fluid viscosity and flow parameter influence values ​​corresponding to the temperature of the liquid are weightedly calculated to obtain the adaptive adjustment factor corresponding to the flow velocity.

[0025] Preferably, the data processing and analysis module is also used to perform fault monitoring and analysis on key components in the production process of copper-clad aluminum materials, specifically:

[0026] Identify key components in the copper-clad aluminum material production process, including smelting equipment, delivery pipelines, sensors and valves on pipelines, molding equipment, and monitoring equipment;

[0027] Obtaining the operating parameter data corresponding to the key components, setting the preset operating parameter data of the key components according to the equipment specifications and performance parameters corresponding to the key components, and performing difference calculation between the values ​​of any parameter in the operating parameter data and the corresponding parameter in the preset operating parameter data to obtain the operating parameter difference;

[0028] Identify the maintenance cycle of key components and mark the time zone within the current maintenance cycle as the operation and maintenance time zone;

[0029] Collect statistical indicators of operating parameter data within the operation and maintenance time zone, including mean, variance, maximum and minimum values; perform weighted calculation on the operating parameter difference and statistical indicators to obtain the reference value corresponding to the operating parameter data parameter; perform weighted calculation on the reference values ​​of all parameters in the operating parameter data of key components to obtain the set value; set the equipment fault range group, including the normal range of equipment, the abnormal range of equipment and the fault range of equipment; match the set value with the equipment fault range group, if the set value is in the normal range of equipment, generate normal equipment signaling; if the set value is in the abnormal range of equipment, generate abnormal equipment signaling; if the set value is in the fault range of equipment, generate equipment fault signaling.

[0030] Preferably, the corresponding control operation is performed according to the adaptive adjustment signaling in the analysis and processing result, specifically:

[0031] When receiving the adaptive regulation signal corresponding to the flow rate, the flow regulation device on the corresponding pipeline is adjusted according to the adaptive regulation factor corresponding to the flow rate to adjust the valve opening;

[0032] When receiving the adaptive adjustment signal corresponding to the flow velocity, the speed of the power equipment regulator on the corresponding pipeline is driven according to the adaptive adjustment factor corresponding to the flow velocity to change the flow velocity;

[0033] When receiving the adaptive regulation signal corresponding to the pressure, the output power of the pressure-related regulation device on the corresponding pipeline is controlled according to the adaptive regulation factor corresponding to the pressure;

[0034] When the adaptive adjustment signal corresponding to the temperature is received, the heating efficiency of the smelting equipment connected to the corresponding pipeline is controlled according to the adaptive adjustment factor corresponding to the temperature.

[0035] Preferably, the data analysis and processing module is also used to monitor whether the fluid parameter data of the pipeline meets expectations after the corresponding control operation is performed according to the adaptive adjustment signaling, specifically:

[0036] The moment when the adaptive adjustment signaling is generated is taken as the first moment, and the current moment is taken as the second moment; the time area between the first moment and the second moment is marked as the adaptive adjustment time zone; the flow difference value at any moment in the adaptive adjustment time zone is obtained, and the flow difference values ​​at all moments in the adaptive adjustment time zone are weightedly calculated to obtain a comprehensive flow difference index;

[0037] The comprehensive flow difference index is compared with the preset comprehensive flow parameter threshold. If the comprehensive flow difference index is less than or equal to the comprehensive flow parameter threshold, it means that the corresponding parameter in the fluid parameter data meets expectations; if the comprehensive flow difference index is greater than the comprehensive flow parameter threshold, it means that the corresponding parameter in the fluid parameter data has not yet met expectations;

[0038] The time length of the adaptive adjustment time zone is obtained and marked as the adaptive adjustment time length; an adaptive adjustment threshold is set. If the adaptive adjustment time length is greater than the adaptive adjustment threshold, it means that the adaptive adjustment time is too long. A comprehensive inspection signal is generated and recorded as a long-term adaptive adjustment event, including the adaptive adjustment time zone, the parameters in the fluid parameter data involved, and the adaptive adjustment factors corresponding to the parameters; the comprehensive inspection signal is used to trigger the setting values ​​of key components and long-term adaptive adjustment events to be sent to the intelligent terminal of the corresponding maintenance personnel. The maintenance personnel receive the setting values ​​of key components and long-term adaptive adjustment events through the intelligent terminal to perform maintenance on the key components.

[0039] Compared with the related art, the dual-liquid flow control system for copper-clad aluminum material production provided by the present invention has the following beneficial effects:

[0040] The present invention realizes automatic high-precision control of the flow of molten copper and molten aluminum. The task acquisition module accurately calculates the initial valve opening and flow rate, and the flow control execution module makes precise adjustments. In combination with the data acquisition and processing module, the fluid parameters are carefully analyzed. Once a parameter abnormality is found, it is immediately fed back to the flow control execution module for dynamic adjustment to ensure that the copper layer is evenly coated on the aluminum core and tightly bonded, which can effectively avoid the inclusion defect problem caused by the unstable flow of molten copper and molten aluminum.

[0041] The present invention can generate adaptive adjustment signals according to the real-time changes of fluid parameters in production, and perform targeted regulation of flow rate, flow velocity, pressure and temperature according to corresponding adaptive adjustment factors, thereby realizing automatic control of the flow of molten copper and molten aluminum. The adaptive adjustment function enables it to achieve stable operation in a complex production environment with temperature and pressure fluctuations and changes in raw material properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 This is a principle block diagram of the dual-liquid flow control system provided by the present invention for the production of copper-clad aluminum materials. DETAILED DESCRIPTION

[0043] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. 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.

[0044] The terms used in this disclosure are for the purpose of describing specific embodiments only and are not intended to limit the disclosure. The singular forms of "class", "group" and "the" used in this disclosure and the appended claims are also intended to include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0045] It should be understood that although the terms first, second, third, etc. may be used in the present disclosure to describe various information, such information should not be limited to these terms. These terms are only used to distinguish the same type of information from each other. For example, without departing from the scope of the present disclosure, the first information may also be referred to as the second information, and similarly, the second information may also be referred to as the first information. Depending on the context, the word "if" as used herein may be interpreted as "at the time of" or "when" or "in response to determining".

[0046] Please refer to Figure 1 . Dual-liquid flow control system for copper-clad aluminum material production, including:

[0047] A pipeline network, the pipeline network includes a main pipeline and a branch pipeline; the main pipeline and the branch pipeline are used to transport molten copper and molten aluminum, and flow regulating devices are arranged at key nodes of the pipeline network;

[0048] The task acquisition module is used to calculate the valve opening and flow rate corresponding to the copper liquid and the aluminum liquid in the initial state according to the preset production process requirements of the copper-clad aluminum material, and mark the valve opening and flow rate corresponding to the copper liquid and the aluminum liquid as the initial control signal;

[0049] A data acquisition module is used to collect fluid parameter data on the copper liquid and aluminum liquid pipelines during the production process of copper-clad aluminum materials, and transmit the fluid parameter data to the data processing and analysis module;

[0050] The data processing and analysis module is used to receive the fluid parameter data for analysis and processing to obtain the analysis and processing results; the analysis and processing results include the flow parameter difference value, statistical index, adaptive adjustment signaling and adaptive adjustment factors corresponding to the parameters in the fluid parameter data;

[0051] The flow control execution module is electrically connected to the flow regulating device; after receiving the initial control signal, it drives the valve actuator to adjust the valve to the corresponding opening position according to the valve opening value set in the initial control signal; it is also used to receive the analysis and processing results, and execute the corresponding control operation according to the adaptive adjustment signal in the analysis and processing results.

[0052] In the present application, the data acquisition module includes a number of piezoresistive pressure sensors, thermocouple temperature sensors, flow sensors, and flow velocity sensors arranged along the copper liquid and aluminum liquid pipelines; among them, the flow sensor can adopt a turbine flow sensor or an electromagnetic flow sensor, and the flow velocity sensor can adopt an ultrasonic flow velocity sensor or a Pitot tube flow velocity sensor.

[0053] It should be noted that the pressure sensors, flow sensors, temperature sensors, and flow velocity sensors are all equipped with redundant backup sensors. For example, the flow sensors and temperature sensors are equipped with two sets of primary and secondary sensors. When the primary sensor generates a device failure signal, it switches to the secondary sensor to ensure data continuity and prevent control errors due to data loss.

[0054] In the present application, the data acquisition module includes a number of piezoresistive pressure sensors, thermocouple temperature sensors, flow sensors, and flow velocity sensors arranged along the copper liquid and aluminum liquid pipelines; among them, the flow sensor can adopt a turbine flow sensor or an electromagnetic flow sensor, and the flow velocity sensor can adopt an ultrasonic flow velocity sensor or a Pitot tube flow velocity sensor.

[0055] In the present application, fluid parameter data include flow-related parameters, flow velocity-related parameters, pressure-related parameters, temperature-related parameters and fluid physical property parameters in the copper liquid and aluminum liquid pipelines; flow-related parameters include flow rate and flow stability, flow velocity-related parameters include flow velocity and flow velocity uniformity, pressure-related parameters include static pressure and dynamic pressure, temperature-related parameters include fluid temperature and temperature uniformity, and fluid physical property parameters include viscosity and density.

[0056] In this application, the fluid parameter data is received for analysis and processing, and the specific analysis is as follows:

[0057] Identify the preset production process requirements of the current copper-clad aluminum material, and extract the preset fluid parameter data corresponding to the copper liquid and aluminum liquid from the production process requirements;

[0058] The copper and aluminum liquid pipelines are divided into several local pipelines; the fluid parameter data on the local pipelines corresponding to the copper and aluminum liquids are obtained; the traditional overall monitoring is easy to miss local anomalies, but after dividing the local pipelines, the flow deviation, flow velocity fluctuation and other abnormal conditions of the specific pipe section can be accurately located, which is conducive to quickly finding the root cause of the problem and stopping the loss in time;

[0059] The difference between any parameter in the fluid parameter data on the local pipeline and the value of the corresponding parameter in the preset fluid parameter data is calculated to obtain a flow parameter difference value;

[0060] Set the monitoring time zone, obtain the flow parameter difference value of the fluid parameter data at any collection time in the monitoring time zone, and count the statistical indicators of the fluid parameter data in the monitoring time zone; the statistical indicators include mean value, variance, maximum value, and minimum value; through statistical indicators, we can gain insight into the changes in fluid parameters from a dynamic and overall perspective, among which the variance highlights the severity of fluctuations, the mean reflects the overall level, and the maximum value assists in judging extreme working conditions. Excessive variance means that the production process is unstable, which may cause uneven copper layer thickness; the mean deviates from the preset value, warning that the overall process parameters are out of control;

[0061] The flow parameter difference value and the statistical index are weighted to obtain the local deviation value; the local deviation values ​​of all local pipelines are weighted to obtain the flow parameter influence value corresponding to the parameter in the fluid parameter data; the current anomaly and trend are comprehensively considered through weighted calculation to avoid misadjustment caused by a single instantaneous deviation or ignore the accumulation of potential fluctuations;

[0062] Set the flow parameter threshold, compare the flow parameter impact value with the flow parameter threshold, and if the flow parameter impact value is greater than the flow parameter threshold, generate an adaptive adjustment signal; the adaptive adjustment signal is used to trigger the analysis of the adaptive adjustment factor; by calculating different adjustment factors corresponding to different fluid parameters, the system can adjust the flow rate, flow velocity, pressure, and temperature in a targeted manner to achieve on-demand, precise control, and efficient deviation correction, thereby ensuring smooth production of copper-clad aluminum materials and high product quality, which meets the demands of refined and intelligent management and control of smart manufacturing.

[0063] In this application, the analysis of the adaptive adjustment factor is specifically as follows:

[0064] For the adaptive adjustment signaling corresponding to the flow rate, the pipeline diameter and pipeline length are obtained, and the pipeline diameter, pipeline length and flow parameter influence value corresponding to the flow rate are weightedly calculated to obtain the adaptive adjustment factor corresponding to the flow rate; it should be noted that the pipeline length is related to the resistance loss along the way. The longer the pipeline, the greater the liquid flow resistance and the more obvious the flow loss. The weighted calculation of these two key parameters and the flow parameter influence value allows the generated adaptive adjustment factor to fully consider the core factors affecting the flow rate. The flow control execution module accurately adjusts the valve or pump and other equipment accordingly, which can quickly and accurately correct the flow deviation, ensure that the copper liquid and the aluminum liquid are accurately mixed according to the flow rate required by the process, and is conducive to the production of copper-clad aluminum products with uniform copper layer thickness and stable quality;

[0065] For the adaptive adjustment signal corresponding to the flow rate, the roughness of the pipeline and the viscosity of the fluid are obtained, and the roughness of the pipeline, the viscosity of the fluid and the flow parameter influence value corresponding to the flow rate are weighted to obtain the adaptive adjustment factor corresponding to the flow rate; it should be noted that the roughness affects the wall friction resistance of the fluid, and the rough inner wall slows down the flow rate of the fluid, especially in the transportation of viscous fluids such as copper liquid and aluminum liquid, the wall friction cannot be ignored; the viscosity of the fluid determines the size of its internal friction. When the viscosity is high, the relative movement between the fluid layers is difficult and the flow rate is limited. Combining these factors with the flow parameter influence value to obtain the adjustment factor can accurately locate the key factors affecting the flow rate, so that the system can adjust the working conditions in a targeted manner after receiving the flow rate adjustment signal, such as fine-tuning the valve opening and changing the pump power, so that the flow rate of copper and aluminum liquids is stable in the ideal range, and prevent product defects such as poor cladding bonding caused by abnormal flow rate;

[0066] For the adaptive adjustment signaling corresponding to the pressure, the pipe diameter, pipe length, roughness, and fluid viscosity of the pipeline are obtained, and the pipe diameter, pipe length, roughness, fluid viscosity, and flow parameter influence values ​​corresponding to the pressure are weighted and calculated to obtain the adaptive adjustment factor corresponding to the pressure; it should be noted that the correlation between the pipe diameter and the flow velocity affects the dynamic pressure. When the pipe diameter decreases and the flow velocity increases, the dynamic pressure rises sharply; the accumulated resistance along the pipeline caused by the length of the pipeline affects the static pressure; the roughness increases the friction resistance, resulting in increased pressure loss; the fluid viscosity determines the viscous resistance and affects the overall pressure distribution. The adjustment factor is calculated in this complex but practical way, which can fully control the source of pressure fluctuations. When the pressure deviates from the preset value and triggers the adjustment signaling, precise measures are taken to maintain a stable pressure environment in the pipeline to avoid pipeline leakage and equipment damage caused by sudden pressure changes, thereby ensuring safe and continuous production;

[0067] For the adaptive adjustment signaling corresponding to the temperature, the density, heat conduction and fluid viscosity of the liquid transported in the pipeline are obtained, and the density, heat conduction, fluid viscosity and flow parameter influence values ​​corresponding to the temperature are weightedly calculated to obtain the adaptive adjustment factor corresponding to the flow rate; it should be noted that density is related to the heat capacity and thermal convection efficiency of the liquid. The density of copper and aluminum liquid changes at different temperatures, affecting the speed of heat transfer; the thermal conductivity characteristics determine the heat exchange rate between the pipeline and the outside world and inside the liquid; the fluid viscosity fluctuates with temperature, and reacts to parameters such as flow rate and pressure; these are combined with the flow parameter influence values ​​to accurately quantify the direction and amplitude of temperature adjustment to ensure that the temperature of the copper and aluminum liquid is appropriate, avoid the deterioration of liquid fluidity and imbalance of chemical reactions due to abnormal temperature, and ensure product molding quality and smooth production process.

[0068] In this application, the data processing and analysis module is also used to perform fault monitoring and analysis on key components in the production process of copper-clad aluminum materials, specifically:

[0069] Identify key components in the copper-clad aluminum material production process, including smelting equipment, delivery pipelines, sensors and valves on pipelines, molding equipment, and monitoring equipment;

[0070] Obtain the operating parameter data corresponding to the key components, set the preset operating parameter data for the operation of the key components according to the equipment specifications and performance parameters corresponding to the key components, and perform difference calculation between the values ​​of any parameter in the operating parameter data and the corresponding parameter in the preset operating parameter data to obtain the operating parameter difference; wherein the operating parameter data is set specifically according to the key equipment, such as for smelting equipment, the collected data includes furnace temperature, heating power, smelting time, etc., for transportation pipelines, the collected data includes pressure, flow rate, flow rate, etc. in the pipeline, for sensors, the collected data includes sensor measurement accuracy, response time, calibration cycle, etc., for valves, the collected data includes valve opening, valve switching frequency, valve sealing, etc., for molding equipment, the collected data includes molding mold temperature, molding pressure, molding speed, etc., for monitoring equipment, the collected data includes the sampling frequency of the monitoring equipment, data transmission stability, and fault alarm frequency;

[0071] Identify the maintenance cycle of key components and mark the time zone within the current maintenance cycle as the operation and maintenance time zone;

[0072] Collect statistical indicators of operating parameter data in the operation and maintenance time zone, including mean value, variance, maximum value and minimum value; perform weighted calculation on the operating parameter difference value and statistical indicators to obtain the reference value corresponding to the operating parameter data parameter; perform weighted calculation on the reference values ​​of all parameters in the operating parameter data of key components to obtain the set value; set the equipment fault range group, including the normal range of equipment, the abnormal range of equipment and the fault range of equipment; match the set value with the equipment fault range group, if the set value is in the normal range of equipment, generate the normal signal of equipment; if the set value is in the abnormal range of equipment, generate the abnormal signal of equipment; if the set value is in the fault range of equipment, generate the fault signal of equipment;

[0073] It should be further explained that when any key component generates a device abnormal signal or a device fault signal, in actual application, the specific details are as follows:

[0074] When the abnormal signaling of the smelting equipment is generated, it indicates that there may be some potential problems with the equipment, and a smelting warning signal is issued to remind the operator to pay attention to the relevant operating parameters. At the same time, maintenance personnel can be arranged to conduct a preliminary inspection of the equipment without affecting production, such as checking whether the connection of the heating element is loose, whether the sealing of the furnace body is good, etc.;

[0075] When the equipment failure signaling of the smelting equipment is generated, it indicates that the equipment fails, production is stopped immediately, and the emergency plan is activated; the emergency plan may activate the redundant equipment corresponding to the equipment;

[0076] When generating abnormal signaling of the equipment in the transmission pipeline, the abnormal warning signal of the transmission pipeline is sent to the maintenance personnel, who will check whether there are slight signs of leakage in the pipeline, whether the pressure sensor and flow rate sensor are working normally, etc. If necessary, they will perform simple maintenance on the pipeline, such as tightening the connection parts;

[0077] When a pipeline equipment failure signal is generated, stop the pipeline immediately and conduct a comprehensive inspection of the pipeline. For example, pressure testing and internal flaw detection are required to find and repair problems such as blockages and serious leaks.

[0078] When generating abnormal signaling of sensors and valves on pipelines, recalibrate the sensors, check whether the valve drive motor and transmission mechanism are normal, or perform maintenance operations such as lubrication on the valves;

[0079] When generating equipment fault signals for sensors and valves on pipelines, if there are redundant devices, switch to using redundant devices, or replace damaged sensors, disassemble and repair valves, or replace damaged parts;

[0080] When generating abnormal equipment signaling of molding equipment, check whether the molding mold is worn, whether the hydraulic system is leaking, etc., and deal with the problems found in a timely manner, such as replacing vulnerable parts of the mold or repairing the leaks in the hydraulic system;

[0081] When a device fault signal of the molding equipment is generated, the molding operation is stopped and the equipment is fully overhauled, such as replacing the mold or overhauling the hydraulic system;

[0082] When generating abnormal signaling of monitoring equipment, calibrate the monitoring equipment to check whether the measuring probe, circuit, etc. are normal to ensure the accuracy of the measurement data.

[0083] When a device fault signal of a monitoring device is generated, stop using the monitoring device and perform a comprehensive repair or replace the faulty parts, such as replacing the probe of a thickness monitor or repairing the circuit board of a component analyzer.

[0084] In this application, the corresponding control operation is performed according to the adaptive adjustment signaling in the analysis and processing result, specifically:

[0085] When receiving the adaptive regulation signal corresponding to the flow rate, the flow regulation device on the corresponding pipeline is adjusted according to the adaptive regulation factor corresponding to the flow rate to adjust the valve opening;

[0086] When receiving the adaptive adjustment signal corresponding to the flow velocity, the speed of the power equipment regulator on the corresponding pipeline is driven according to the adaptive adjustment factor corresponding to the flow velocity to change the flow velocity;

[0087] When receiving the adaptive regulation signal corresponding to the pressure, the output power of the pressure-related regulation device on the corresponding pipeline is controlled according to the adaptive regulation factor corresponding to the pressure;

[0088] When receiving the adaptive adjustment signal corresponding to the temperature, the heating efficiency of the smelting equipment connected to the corresponding pipeline is controlled according to the adaptive adjustment factor corresponding to the temperature;

[0089] It should be noted that by executing the corresponding control operations based on the adaptive adjustment signaling in the analysis and processing results, the flow rate can be accurately controlled, and the valve opening can be adjusted according to the flow adjustment factor. The ratio of copper and aluminum liquids can be accurately controlled to ensure that the copper layer of the product is uniform, the performance meets the standard, and the scrap rate is reduced; the speed of the power equipment is changed according to the flow rate adjustment factor to stabilize the flow rate, which can avoid turbulence and stratification, ensure uniform distribution of the liquid, and improve product quality; the power of the pressure equipment is controlled by the pressure adjustment factor, the pressure in the pipe is maintained stable, the hidden dangers of leakage and rupture are avoided, and the equipment life is extended; the heating efficiency of the smelting equipment is adjusted according to the temperature adjustment factor to meet the temperature control requirements of each stage, assist in the melting, mixing and product forming of raw materials, and comprehensively improve product quality and production stability.

[0090] In the present application, the data analysis and processing module is also used to monitor whether the fluid parameter data of the pipeline meets expectations after the corresponding control operation is performed according to the adaptive adjustment signaling, specifically:

[0091] The moment when the adaptive adjustment signaling is generated is taken as the first moment, and the current moment is taken as the second moment; the time zone between the first moment and the second moment is marked as the adaptive adjustment time zone; the flow parameter difference value at any moment in the adaptive adjustment time zone is obtained and marked as LC, the index of the collection moment in the adaptive adjustment time zone is marked as i, and the corresponding weight at the collection moment i is set to wi, and the weight satisfies < < , weighted calculation is performed on the flow parameter difference values ​​at all times in the adaptive adjustment time zone. The formula is expressed as , and obtain the comprehensive flow variance index Z; where n represents the total number of collection moments in the adaptive adjustment time zone;

[0092] The comprehensive flow difference index is compared with the preset comprehensive flow parameter threshold. If the comprehensive flow difference index is less than or equal to the comprehensive flow parameter threshold, it means that the corresponding parameter in the fluid parameter data meets expectations; if the comprehensive flow difference index is greater than the comprehensive flow parameter threshold, it means that the corresponding parameter in the fluid parameter data has not yet met expectations;

[0093] The time length of the adaptive adjustment time zone is obtained and marked as the adaptive adjustment time length; an adaptive adjustment threshold is set. If the adaptive adjustment time length is greater than the adaptive adjustment threshold, it means that the adaptive adjustment time is too long. A comprehensive inspection signal is generated and recorded as a long-term adaptive adjustment event, including the adaptive adjustment time zone, the parameters in the fluid parameter data involved, and the adaptive adjustment factors corresponding to the parameters; the comprehensive inspection signal is used to trigger the setting values ​​of key components and long-term adaptive adjustment events to be sent to the intelligent terminal of the corresponding maintenance personnel. The maintenance personnel receive the setting values ​​of key components and long-term adaptive adjustment events through the intelligent terminal to perform maintenance on the key components.

[0094] It should be noted that the data analysis and processing module also monitors and analyzes the fluid parameter data after adaptive adjustment, which can achieve accurate quantitative evaluation of the control effect, intelligent warning of abnormalities, and efficient linkage maintenance. The comprehensive flow difference index can be used to intuitively judge whether the fluid parameters meet the standards, helping production to accurately meet process requirements; based on the time threshold monitoring, the problem of long adjustment time can be found in time to prevent abnormal operation of the system; comprehensive inspection signaling can push key information to maintenance personnel with one click, so that they can accurately carry out maintenance, reduce downtime, and fully guarantee the efficient and stable production of copper-clad aluminum.

[0095] Those skilled in the art will readily appreciate other embodiments of the present invention after considering the specification and practicing the invention disclosed herein. This application is intended to cover any variations, uses or adaptations of the present invention that follow the general principles of the present invention and include common knowledge or customary techniques in the art that are not disclosed in this disclosure. The specification and examples are to be considered exemplary only, and the true scope and spirit of the present invention are indicated by the following claims.

[0096] It should be understood that the present invention is not limited to the exact construction that has been described above and shown in the drawings and that various modifications and changes may be made without departing from the scope thereof. The scope of the present invention is limited only by the appended claims.

Claims

1. A dual-liquid flow control system for the production of copper-clad aluminum materials, characterized in that: include: A pipeline network, the pipeline network comprising a main pipeline and branch pipelines; the main pipeline and branch pipelines are used to transport molten copper and molten aluminum, and flow regulating devices are provided at key nodes of the pipeline network; The task acquisition module is used to calculate the valve opening and flow rate corresponding to the copper liquid and the aluminum liquid in the initial state according to the preset production process requirements of the copper-clad aluminum material, and mark the valve opening and flow rate corresponding to the copper liquid and the aluminum liquid as the initial control signal; A data acquisition module is used to collect fluid parameter data on the copper liquid and aluminum liquid pipelines during the production process of copper-clad aluminum materials, and transmit the fluid parameter data to the data processing and analysis module; The data processing and analysis module is used to receive the fluid parameter data for analysis and processing to obtain the analysis and processing results; the analysis and processing results include the flow parameter difference value, statistical index, adaptive adjustment signaling and adaptive adjustment factors corresponding to the parameters in the fluid parameter data; Among them, the fluid parameter data is received for analysis and processing, and the specific analysis is as follows: Identify the preset production process requirements of the current copper-clad aluminum material, and extract the preset fluid parameter data corresponding to the copper liquid and aluminum liquid from the production process requirements; The copper liquid and aluminum liquid pipelines are divided into several local pipelines; the fluid parameter data on the local pipelines corresponding to the copper liquid and the aluminum liquid are obtained; the difference between any parameter in the fluid parameter data on the local pipeline and the value of the corresponding parameter in the preset fluid parameter data is calculated to obtain the flow parameter difference value; Set the monitoring time zone, obtain the flow parameter difference value of the fluid parameter data at any collection time in the monitoring time zone, and calculate the statistical indicators of the fluid parameter data in the monitoring time zone; the statistical indicators include the mean value, variance, maximum value, and minimum value; The flow parameter difference value and the statistical index are weighted to obtain the local deviation value; the local deviation values ​​of all local pipelines are weighted to obtain the flow parameter influence value corresponding to the parameter in the fluid parameter data; Set the flow parameter threshold, compare the flow parameter impact value with the flow parameter threshold, and if the flow parameter impact value is greater than the flow parameter threshold, generate adaptive adjustment signaling; the adaptive adjustment signaling is used to trigger the analysis of the adaptive adjustment factor, specifically: For the adaptive regulation signaling corresponding to the flow rate, the pipe diameter and pipe length are obtained, and the pipe diameter, pipe length and flow parameter influence value corresponding to the flow rate are weighted and calculated to obtain the adaptive regulation factor corresponding to the flow rate; For the adaptive adjustment signaling corresponding to the flow velocity, the roughness of the pipeline and the fluid viscosity are obtained, and the roughness of the pipeline, the fluid viscosity and the flow parameter influence value corresponding to the flow velocity are weightedly calculated to obtain the adaptive adjustment factor corresponding to the flow velocity; For the adaptive adjustment signaling corresponding to the pressure, the pipe diameter, pipe length, roughness, and fluid viscosity of the pipeline are obtained, and the pipe diameter, pipe length, roughness, fluid viscosity, and the flow parameter influence value corresponding to the pressure are weighted and calculated to obtain the adaptive adjustment factor corresponding to the pressure; For the adaptive adjustment signaling corresponding to the temperature, the density, heat conduction and fluid viscosity of the liquid transported in the pipeline are obtained, and the density, heat conduction, fluid viscosity and flow parameter influence values ​​corresponding to the temperature are weightedly calculated to obtain the adaptive adjustment factor corresponding to the flow velocity; A flow control execution module, which is electrically connected to the flow regulating device; after receiving the initial control signal, it drives the valve actuator to adjust the valve to the corresponding opening position according to the valve opening value set in the initial control signal; it is also used to receive the analysis and processing results, and execute the corresponding control operation according to the adaptive adjustment signal in the analysis and processing results.

2. The dual-liquid flow control system for copper-clad aluminum material production according to claim 1, characterized in that: The data acquisition module includes a plurality of piezoresistive pressure sensors, thermocouple temperature sensors, flow sensors, and flow velocity sensors arranged along the copper liquid and aluminum liquid pipelines; wherein the flow sensor can be a turbine flow sensor or an electromagnetic flow sensor, and the flow velocity sensor can be an ultrasonic flow velocity sensor or a Pitot tube flow velocity sensor.

3. The dual-liquid flow control system for copper-clad aluminum material production according to claim 1, characterized in that: The fluid parameter data include flow-related parameters, flow velocity-related parameters, pressure-related parameters, temperature-related parameters and fluid physical property parameters in the copper liquid and aluminum liquid pipelines; flow-related parameters include flow rate and flow stability, flow velocity-related parameters include flow velocity and flow velocity uniformity, pressure-related parameters include static pressure and dynamic pressure, temperature-related parameters include fluid temperature and temperature uniformity, and fluid physical property parameters include viscosity and density.

4. The dual-liquid flow control system for copper-clad aluminum material production according to claim 1, characterized in that: The data processing and analysis module is also used to perform fault monitoring and analysis on key components in the production process of copper-clad aluminum materials, specifically: Identify key components in the copper-clad aluminum material production process, including smelting equipment, delivery pipelines, sensors and valves on pipelines, molding equipment, and monitoring equipment; Obtaining the operating parameter data corresponding to the key components, setting the preset operating parameter data of the key components according to the equipment specifications and performance parameters corresponding to the key components, and performing difference calculation between the values ​​of any parameter in the operating parameter data and the corresponding parameter in the preset operating parameter data to obtain the operating parameter difference; Identify the maintenance cycle of key components and mark the time zone within the current maintenance cycle as the operation and maintenance time zone; Statistical indicators of operating parameter data within the operation and maintenance time zone, including average value, variance, maximum value, and minimum value; Perform weighted calculation on the difference between the operation parameters and the statistical index to obtain the reference value corresponding to the operation parameter data parameter; perform weighted calculation on the reference values ​​of all parameters in the operation parameter data of the key components to obtain the setting value; Set the device fault range group, including the normal range, abnormal range and fault range; match the set shadow value with the device fault range group. If the set shadow value is within the normal range, a normal device signal is generated; if the set shadow value is within the abnormal range, a fault signal is generated; if the set shadow value is within the fault range, a fault signal is generated.

5. The dual-liquid flow control system for copper-clad aluminum material production according to claim 1, characterized in that: According to the adaptive adjustment signaling in the analysis and processing results, the corresponding control operation is performed, specifically: When receiving the adaptive regulation signal corresponding to the flow rate, the flow regulation device on the corresponding pipeline is adjusted according to the adaptive regulation factor corresponding to the flow rate to adjust the valve opening; When receiving the adaptive adjustment signal corresponding to the flow velocity, the speed of the power equipment regulator on the corresponding pipeline is driven according to the adaptive adjustment factor corresponding to the flow velocity to change the flow velocity; When receiving the adaptive regulation signal corresponding to the pressure, the output power of the pressure-related regulation device on the corresponding pipeline is controlled according to the adaptive regulation factor corresponding to the pressure; When the adaptive adjustment signal corresponding to the temperature is received, the heating efficiency of the smelting equipment connected to the corresponding pipeline is controlled according to the adaptive adjustment factor corresponding to the temperature.

6. The dual-liquid flow control system for copper-clad aluminum material production according to claim 1, characterized in that: The data processing and analysis module is also used to monitor whether the fluid parameter data of the pipeline meets expectations after the corresponding control operation is performed according to the adaptive adjustment signaling, specifically: The time when the adaptive adjustment signaling is generated is taken as the first time, and the current time is taken as the second time; and the time area between the first time and the second time is marked as the adaptive adjustment time area; Obtain the flow difference value at any time in the adaptive adjustment time zone, and perform weighted calculation on the flow difference values ​​at all times in the adaptive adjustment time zone to obtain a comprehensive flow difference index; The comprehensive flow difference index is compared with the preset comprehensive flow parameter threshold. If the comprehensive flow difference index is less than or equal to the comprehensive flow parameter threshold, it means that the corresponding parameter in the fluid parameter data meets expectations; if the comprehensive flow difference index is greater than the comprehensive flow parameter threshold, it means that the corresponding parameter in the fluid parameter data has not yet met expectations; The time length of the adaptive adjustment time zone is obtained and marked as the adaptive adjustment time length; An adaptive adjustment threshold is set. If the adaptive adjustment time is greater than the adaptive adjustment threshold, it means that the adaptive adjustment time is too long. A comprehensive inspection signal is generated and recorded as a long-term adaptive adjustment event, including the adaptive adjustment time zone, the parameters in the fluid parameter data involved, and the adaptive adjustment factors corresponding to the parameters. The comprehensive inspection signal is used to trigger the sending of the setting values ​​of key components and long-term adaptive adjustment events to the smart terminal of the corresponding maintenance personnel. The maintenance personnel receive the setting values ​​of key components and long-term adaptive adjustment events through the smart terminal to perform maintenance on the key components.

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