Steel wire sorbite quenching liquid adding process optimization method and system

Abstract

The invention is applicable to the technical field of quenching liquid adding process optimization, and provides a steel wire sorbite quenching liquid adding process optimization method and system, which are used for acquiring real-time quenching liquid adding process video data of a target quenching tank, and determining a plurality of bubble flowing paths according to the real-time quenching liquid adding process video data. Real-time quenching liquid adding process video data of a target quenching tank can be obtained, and a plurality of bubble flowing paths including bubble generating points and bubble breaking points can be determined based on the data. The method comprises the following steps: firstly, analyzing a flowing path of each bubble, identifying a generation point and a breaking point of the bubble, and acquiring relevant data such as a liquid injection angle, pressure and flow of a first quenching liquid injection port near the breaking point of each bubble; then, by integrating the data, a preliminary injection port adding optimization scheme is generated, so that the condition of bubble breaking can be effectively copied to other areas;

Description

Technical Field

[0001] The invention belongs to the technical field of quenching liquid addition process optimization, and in particular relates to a method and system for optimizing the quenching liquid addition process for steel wire sorbitization. Background Art

[0002] The sorbitization treatment of steel wire is an extremely important step in the steel wire production process. It aims to transform the steel wire into a structure with sorbite structure through quenching process, thereby improving its strength, toughness and wear resistance. The addition process of quenching liquid is crucial to the entire sorbitization treatment, which can directly affect the cooling rate and final structure of the steel wire. However, during the addition process of quenching liquid, bubbles often appear at the contact surface between the steel wire surface and the quenching liquid. These bubbles will hinder the full contact between the quenching liquid and the steel wire, resulting in uneven cooling, which will lead to inconsistent local hardness and structural defects in the steel wire, and even affect its mechanical properties. How to effectively control the generation of bubbles and eliminate their negative effects has always been the research focus in this field.

[0003] The current quenching liquid addition technology usually relies on fixed injection angles, pressures and flow rates for control, but does not fully consider the specific location of bubble generation and its flow path. In actual production, bubbles tend to be generated and burst in specific areas, especially in areas with uneven injection or large pressure fluctuations, where the frequency of bubble generation increases significantly. These bubbles form an insulating layer on the surface of the steel wire, hindering effective cooling, resulting in surface defects or decreased mechanical properties of the steel wire after quenching. Although the existing technology can reduce bubbles through simple flow and pressure adjustments, it cannot fundamentally eliminate bubbles, nor can it achieve precise control of the bubble flow path.

[0004] Therefore, the existing technology has obvious defects in bubble control and cannot effectively regulate the generation and collapse of bubbles from the source. This not only leads to a decrease in cooling efficiency, but also increases the scrap rate of workpieces and subsequent processing costs. In response to this problem, the present invention proposes an optimization solution that monitors the bubble flow path in real time and adjusts the injection parameters based on the bubble collapse point. Summary of the invention

[0005] The object of the present invention is to provide a method and system for optimizing the process of adding quenching liquid for sorbitization of steel wire, aiming to solve the problems raised in the background technology.

[0006] The present invention is achieved by providing a method for optimizing the process of adding quenching liquid for steel wire sorbitization, the method comprising: Acquire real-time quenching liquid adding process video data of the target quenching tank, and determine multiple bubble flow paths according to the real-time quenching liquid adding process video data; Determine the bubble generation point and bubble bursting point of each bubble flow path, and obtain the injection-related data of the first quenching liquid injection port closest to each bubble bursting point, and generate initial injection port addition optimization data based on the injection-related data of multiple first quenching liquid injection ports; Acquire injection-related data of the second quenching liquid injection ports that are closest to different bubble generation points, and modify the injection-related data of each second quenching liquid injection port according to the initial injection port addition optimization data; Observe and record the injection effect of the modified second quenching liquid injection port, and focus on analyzing whether the number of bubbles at the bubble generation point has decreased. If the number of bubbles has not decreased, continue to adjust the initial injection port to add optimization data, and repeatedly apply it to the second quenching liquid injection port.

[0007] As a further limitation of the technical solution of the embodiment of the present invention, the injection-related data includes the injection angle, the injection pressure and the injection flow rate.

[0008] As a further limitation of the technical solution of the embodiment of the present invention, the steps of obtaining real-time quenching liquid adding process video data of the target quenching tank, and determining multiple bubble flow paths according to the real-time quenching liquid adding process video data include: Acquire real-time quenching liquid adding process video data of the target quenching tank; Intelligently analyze the real-time quenching liquid addition process video data based on computer vision technology, and determine the bubble generation location, movement trajectory and bursting location; According to the generation position, movement trajectory and collapse position of the bubble, a bubble flow path from the generation to the collapse of the bubble is generated.

[0009] As a further limitation of the technical solution of the embodiment of the present invention, the step of determining the bubble generation point and the bubble collapse point of each bubble flow path, and obtaining the injection-related data of the first quenching liquid injection port closest to each bubble collapse point, and integrating the injection-related data of multiple first quenching liquid injection ports to generate the initial injection port addition optimization data includes: Determine a bubble generation point and a bubble collapse point of each bubble flow path according to a bubble generation position and a bubble collapse position in each bubble flow path; Determine the first quenching liquid injection port closest to each bubble burst point, and obtain injection-related data of the first quenching liquid injection port corresponding to each bubble burst point; Initial injection port addition optimization data is generated based on the integration of injection-related data of multiple first quenching liquid injection ports.

[0010] As a further limitation of the technical solution of the embodiment of the present invention, the step of integrating the injection-related data of the plurality of first quenching liquid injection ports to generate the initial injection port addition optimization data includes: Acquire the injection angles, injection pressures and injection flow rates of the plurality of first quenching liquid injection ports, and generate an injection angle curve graph, an injection pressure curve graph and an injection flow curve graph respectively according to the plurality of injection angles, injection pressures and injection flow rates; From the injection angle curve, injection pressure curve and injection flow curve, select the point with the most stable curve change and the best corresponding effect as the optimal injection angle, optimal injection pressure and optimal injection flow respectively; The optimal injection angle, optimal injection pressure and optimal injection flow rate are integrated to obtain the initial injection port addition optimization data.

[0011] As a further limitation of the technical solution of the embodiment of the present invention, the steps of obtaining the injection-related data of the second quenching liquid injection ports that are closest to different bubble generation points, and modifying the injection-related data of each second quenching liquid injection port according to the initial injection port adding optimization data include: Determine the second quenching liquid injection port that is closest to different bubble generation points; Obtaining the injection angle, injection pressure and injection flow rate of the second quenching liquid injection port corresponding to different bubble generation points; The injection angle, injection pressure and injection flow rate of the second quenching liquid injection port corresponding to different bubble generation points are modified to the optimal injection angle, optimal injection pressure and optimal injection flow rate.

[0012] As a further limitation of the technical solution of the embodiment of the present invention, the steps of observing and recording the injection effect of the modified second quenching liquid injection port, focusing on analyzing whether the number of bubbles at the bubble generation point is reduced, and if the number of bubbles is not reduced, continuing to adjust the initial injection port to add optimization data, and repeatedly applying it to the second quenching liquid injection port include: Observe and record the injection effect of the modified second quenching liquid injection port, and focus on analyzing whether the number of bubbles at the bubble generation point has been reduced; If the number of bubbles does not decrease, select the second most stable point in the injection angle curve, injection pressure curve, and injection flow rate curve as the new injection angle, injection pressure, and injection flow rate, respectively; Apply the new injection angle, injection pressure and injection flow rate to the second quenching liquid injection port, and continue to observe the changes in the number of bubbles. If the bubbles still do not decrease significantly, further select the third stable point in the curve for subsequent optimization and adjustment until the number of bubbles reaches the ideal level.

[0013] A steel wire sorbitization quenching liquid addition process optimization system, the system comprises: a bubble flow path determination module, an initial injection port addition optimization data generation module, an injection related data modification module and an initial injection port addition optimization data adjustment module, wherein: A bubble flow path determination module is used to obtain real-time quenching liquid addition process video data of a target quenching tank, and determine multiple bubble flow paths according to the real-time quenching liquid addition process video data; An initial injection port addition optimization data generation module is used to determine the bubble generation point and the bubble bursting point of each bubble flow path, and obtain the injection related data of the first quenching liquid injection port closest to each bubble bursting point, and generate the initial injection port addition optimization data according to the injection related data of multiple first quenching liquid injection ports, wherein the injection related data includes the injection angle, the injection pressure and the injection flow rate; A liquid injection related data modification module, used to obtain liquid injection related data of the second quenching liquid injection ports that are closest to different bubble generation points, and modify the liquid injection related data of each second quenching liquid injection port according to the initial injection port addition optimization data; The initial injection port adds an optimization data adjustment module, which is used to observe and record the injection effect of the modified second quenching liquid injection port, focusing on analyzing whether the number of bubbles at the bubble generation point has decreased. If the number of bubbles has not decreased, continue to adjust the initial injection port to add optimization data, and repeatedly apply it to the second quenching liquid injection port.

[0014] As a further limitation of the technical solution of the embodiment of the present invention, the bubble flow path determination module specifically includes: A video data acquisition unit, used to acquire real-time quenching liquid addition process video data of a target quenching tank; A video data analysis unit, which is used to intelligently analyze the real-time quenching liquid addition process video data based on computer vision technology, and determine the bubble generation location, movement trajectory and bursting location; The bubble flow path generating unit is used to generate a bubble flow path from the generation to the collapse of the bubble according to the generation position, movement trajectory and collapse position of the bubble.

[0015] As a further limitation of the technical solution of the embodiment of the present invention, the initial injection port addition optimization data generation module specifically includes: a bubble point determination unit, for determining a bubble generation point and a bubble collapse point of each bubble flow path according to a bubble generation position and a bubble collapse position in each bubble flow path; A liquid injection related data acquisition unit, used to determine the first quenching liquid injection port closest to each bubble burst point, and acquire liquid injection related data of the first quenching liquid injection port corresponding to each bubble burst point; The liquid injection related data integration unit is used to generate initial injection port addition optimization data based on the liquid injection related data of multiple first quenching liquid injection ports.

[0016] Compared with the prior art, the present invention has the following beneficial effects: This technical solution obtains the real-time quenching liquid addition process video data of the target quenching tank, and determines multiple bubble flow paths based on this data, including the bubble generation point and bursting point. First, by analyzing each bubble flow path, the bubble generation point and bursting point are identified, and the relevant data such as the injection angle, pressure and flow rate of the first quenching liquid injection port near each bubble bursting point are obtained. Then, by integrating these data, a preliminary injection port addition optimization plan is generated to ensure that the bubble bursting conditions can be effectively replicated to other areas.

[0017] Next, obtain the injection-related data of the second quenching liquid injection port that is closest to different bubble generation points, and adjust the data of these second injection ports according to the preliminary optimization plan. This process aims to eliminate bubbles in areas where bubbles may originally be generated through optimized injection methods. The effectiveness of the adjustment can be judged by observing and recording the injection effect of the modified second quenching liquid injection port, especially the change in the number of bubbles at the bubble generation point. If the number of bubbles has not decreased significantly, continue to make secondary or multiple adjustments based on the preliminary optimization data until the number of bubbles is significantly reduced and the ideal quenching effect is achieved.

[0018] This solution is based on scientific fluid dynamics and bubble behavior analysis, and accurately optimizes the injection conditions in a data-driven manner to ensure that bubbles are gradually eliminated during the quenching process. This method is highly operational and practical, and can effectively improve the uniformity of the quenching process and the quality of the workpiece. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 A flowchart of a method provided by an embodiment of the present invention; Figure 2 A flow chart of determining a bubble flow path according to real-time quenching liquid addition process video data in a method provided by an embodiment of the present invention; Figure 3 A flow chart of generating initial injection port addition optimization data according to the integration of injection-related data of multiple first quenching liquid injection ports in the method provided in an embodiment of the present invention; Figure 4 A flow chart of generating initial injection port addition optimization data in the method provided by an embodiment of the present invention; Figure 5 A flow chart of modifying the injection-related data of each second quenching liquid injection port in the method provided in an embodiment of the present invention; Figure 6 A flow chart of adjusting the initial injection port to add optimization data in the method provided in an embodiment of the present invention and repeatedly applying the optimization data to the second quenching liquid injection port; Figure 7 An application architecture diagram of a system provided by an embodiment of the present invention; Figure 8 A structural block diagram of a bubble flow path determination module in a system provided by an embodiment of the present invention; Fig. 9 A structural block diagram of adding an optimization data generation module to the initial injection port in the system provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0021] It is understood that the terms "first", "second", etc. used in this application may be used herein to describe various elements, but unless otherwise specified, these elements are not limited by these terms. These terms are only used to distinguish a first element from another element. For example, without departing from the scope of this application, a first xx script may be referred to as a second xx script, and similarly, a second xx script may be referred to as a first xx script.

[0022] Figure 1 A flow chart of a method provided by an embodiment of the present invention is shown.

[0023] Specifically, a method for optimizing the process of adding quenching liquid for sorbitization of steel wire comprises the following steps: Step S100, obtaining real-time quenching liquid adding process video data of the target quenching tank, and determining multiple bubble flow paths according to the real-time quenching liquid adding process video data. The injection related data includes injection angle, injection pressure and injection flow rate.

[0024] Specifically, Figure 2 A flow chart for determining the bubble flow path based on real-time quenching liquid addition process video data is shown.

[0025] The process of obtaining the real-time quenching liquid adding process video data of the target quenching tank and determining the multiple bubble flow paths according to the real-time quenching liquid adding process video data specifically includes the following steps: Step S101, obtaining real-time quenching liquid adding process video data of the target quenching tank; Step S102, intelligently analyzing the real-time quenching liquid addition process video data based on computer vision technology, and determining the bubble generation position, movement trajectory and bursting position; Step S103, generating a bubble flow path from the generation to the collapse of the bubble according to the generation position, movement trajectory and collapse position of the bubble.

[0026] In an embodiment of the present invention, obtaining real-time video data of the quenching liquid addition process requires installing a high-resolution industrial camera or a high-speed camera at a key position of the quenching tank. These cameras should have properties such as high temperature resistance and waterproofness, and be able to capture the flow of the quenching liquid and the formation, movement, and collapse of bubbles during the quenching process. The camera is connected to a computer system, and the video data is transmitted to the computer in real time for subsequent analysis. In this way, the flow of the quenching liquid can be recorded in real time and used for subsequent processing.

[0027] To intelligently analyze video data based on computer vision technology, the real-time quenching video must first be preprocessed. Common image processing techniques such as denoising, grayscale processing, and contrast enhancement can improve the clarity of the image and highlight the characteristics of the bubbles. In the processed image, the presence of bubbles is identified by edge detection algorithms (such as the Sobel operator) or convolutional neural networks (CNN). Next, the target tracking algorithm (such as optical flow or Kalman filtering) is used to track the movement trajectory of each bubble, and the entire process from bubble generation to disappearance can be accurately recorded.

[0028] As the bubbles move and change position, the computer vision system can analyze the bubble generation location, movement path, and burst location in real time. The system determines the bubble life cycle by the changes in bubble size and shape, and generates a complete bubble flow path diagram. These data are displayed through visualization tools to help engineers optimize quenching liquid injection parameters and improve bubble problems during quenching. This process realizes automated bubble monitoring and path analysis, which can be applied and adjusted in real time during actual production.

[0029] Furthermore, the method for optimizing the process of adding quenching liquid for steel wire sorbitization further comprises the following steps: Step S200, determine the bubble generation point and bubble bursting point of each bubble flow path, and obtain the injection related data of the first quenching liquid injection port closest to each bubble bursting point, and integrate the injection related data of multiple first quenching liquid injection ports to generate initial injection port addition optimization data.

[0030] Specifically, Figure 3 A flow chart is shown for generating initial injection port addition optimization data based on integration of injection-related data of multiple first quenching liquid injection ports.

[0031] Among them, determining the bubble generation point and the bubble collapse point of each bubble flow path, and obtaining the injection-related data of the first quenching liquid injection port closest to each bubble collapse point, and integrating the injection-related data of multiple first quenching liquid injection ports to generate the initial injection port addition optimization data specifically includes the following steps: Step S201, determining a bubble generation point and a bubble collapse point of each bubble flow path according to a bubble generation position and a bubble collapse position in each bubble flow path; Step S202, determining the first quenching liquid injection port closest to each bubble collapse point, and obtaining injection-related data of the first quenching liquid injection port corresponding to each bubble collapse point; Step S203, generating initial injection port addition optimization data based on the integration of injection-related data of the plurality of first quenching liquid injection ports.

[0032] In an embodiment of the present invention, in order to determine the first quenching liquid injection port closest to each bubble burst point, it is first necessary to accurately locate the bubble burst position by computer vision technology. These position information will be recorded in the form of coordinates and reflected in the three-dimensional space of the quenching tank. Subsequently, the position of each bubble burst point is compared with the coordinates of all quenching liquid injection ports in the quenching tank, and the distance between the bubble burst point and each injection port is calculated. The shortest distance between the bubble burst point and the injection port is calculated by a distance formula (such as Euclidean distance), and finally the quenching liquid injection port closest to each other is selected as the associated injection port of the bubble burst point.

[0033] Once the injection port closest to the bubble bursting point is found, the injection data of the injection port (including injection angle, pressure and flow rate, etc.) can be further analyzed to optimize the flow of the quenching liquid, burst the bubbles as quickly as possible and reduce the generation of new bubbles.

[0034] The target quenching tank is usually equipped with multiple quenching liquid injection ports, which are evenly distributed at different positions in the quenching tank to ensure that the quenching liquid can cover the entire surface of the steel wire or workpiece. During the design process, the arrangement of the injection ports usually takes into account the size of the workpiece, the flow path of the quenching liquid, and the cooling efficiency. For example, the injection ports can be arranged symmetrically along both sides of the quenching tank, or distributed at different heights and angles to minimize local uneven cooling and bubble accumulation. Different injection ports work independently through an intelligent control system, and the injection parameters (such as angle, pressure, flow rate, etc.) can be dynamically adjusted according to the distribution of bubble generation to ensure that the bubbles are effectively controlled and the workpiece is cooled evenly during the entire quenching process.

[0035] Specifically, Figure 4 A flow chart for generating initial sprue addition optimization data is shown.

[0036] The process of integrating the injection-related data of the plurality of first quenching liquid injection ports to generate the initial injection port addition optimization data specifically includes the following steps: Step S2031, obtaining the injection angles, injection pressures and injection flow rates of the plurality of first quenching liquid injection ports, and generating an injection angle curve graph, an injection pressure curve graph and an injection flow rate curve graph according to the plurality of injection angles, injection pressures and injection flow rates; Step S2032, from the injection angle curve graph, the injection pressure curve graph, and the injection flow rate curve graph, select the point with the most stable curve change and the best corresponding effect as the optimal injection angle, the optimal injection pressure, and the optimal injection flow rate, respectively; Step S2033, integrating the optimal injection angle, the optimal injection pressure and the optimal injection flow rate to obtain the initial injection port addition optimization data.

[0037] In an embodiment of the present invention, the point with the most stable curve change and the best corresponding effect is selected as the optimal injection angle, pressure and flow rate, which can significantly reduce the generation of bubbles. During the quenching process, the formation of bubbles often leads to uneven cooling, thereby affecting the quality of the workpiece. By determining the optimal injection parameters, the quenching liquid can cover the surface of the workpiece in a more uniform manner, reducing turbulence and bubble generation caused by excessive local flow rate. The optimal injection angle can ensure that the contact between the flow direction of the quenching liquid and the workpiece surface is more stable, avoiding turbulence; the optimal injection pressure can maintain an appropriate injection intensity to prevent the increase of bubbles caused by excessive pressure; and the optimal flow rate ensures uniform coverage of the liquid, reducing local siltation and bubble retention.

[0038] By reducing the generation of bubbles, the entire quenching process becomes more stable and efficient. The reduction of bubbles means that the quenching liquid can fully contact the surface of the workpiece, thereby achieving a more uniform cooling effect and avoiding local over-high or over-low temperatures. In addition, reducing bubbles also helps to reduce the surface defect rate of the workpiece and improve the mechanical properties of the product.

[0039] This optimization based on scientific data, through experiments and analysis, finds the most stable and effective points in each parameter curve, which can further improve the repeatability and stability of the process. In each quenching operation, the injection angle, pressure and flow rate can be kept consistent, so as to maintain a uniform cooling effect in different batches of production and ensure the reliability of product quality.

[0040] Finally, by reducing the generation of bubbles, the energy consumption of the entire quenching process is also optimized. Reducing unnecessary bubble generation and collapse can reduce the flow resistance of the quenching liquid, making the cooling process more efficient and thus reducing energy consumption. This optimization not only improves production efficiency, but also brings cost savings to the company.

[0041] Furthermore, the method for optimizing the process of adding quenching liquid for steel wire sorbitization further comprises the following steps: Step S300, obtaining injection-related data of the second quenching liquid injection ports that are closest to different bubble generation points, and modifying the injection-related data of each second quenching liquid injection port according to the initial injection port addition optimization data.

[0042] Specifically, Figure 5 A flow chart for modifying the injection-related data of each second quenching liquid injection port is shown.

[0043] The steps of obtaining the injection-related data of the second quenching liquid injection ports that are closest to different bubble generation points and modifying the injection-related data of each second quenching liquid injection port according to the initial injection port adding optimization data specifically include the following steps: Step S301, determining the second quenching liquid injection port that is closest to different bubble generation points; Step S302, obtaining the injection angle, injection pressure and injection flow rate of the second quenching liquid injection port corresponding to different bubble generation points; Step S303, modifying the injection angle, injection pressure and injection flow rate of the second quenching liquid injection port corresponding to different bubble generation points to the optimal injection angle, optimal injection pressure and optimal injection flow rate.

[0044] In an embodiment of the present invention, first, it is necessary to monitor the location of bubble generation in the quenching tank in real time through video data or computer vision technology, and accurately record the coordinates of these bubble generation points. Then, the coordinates of these bubble generation points are matched with the coordinates of each second quenching liquid injection port in the quenching tank, and the distance between each bubble generation point and all quenching liquid injection ports is calculated. The Euclidean distance formula is usually used to calculate the spatial distance between these points. By comparing these distances, the system can quickly identify the second quenching liquid injection port closest to the bubble generation point, ensuring that the quenching liquid can reach the bubble generation area by the shortest path, further optimizing the cooling effect.

[0045] By modifying the injection angle, injection pressure and injection flow rate of the second quenching liquid injection port corresponding to the bubble generation point to the optimal parameters, this improved method can effectively eliminate the bubbles originally generated near the bubble generation point. The principle is based on using the bubble collapse point as a reference to "replace" the original bubble generation point by optimizing the injection method. This method utilizes the fluid dynamic environment of the bubble collapse point, that is, the flow characteristics of the quenching liquid in the collapse point area contribute to the natural dissipation of bubbles. By adjusting the injection conditions at the generation point to be similar to the injection conditions at the collapse point, the flow state of the fluid will be optimized, thereby preventing bubbles from forming at the generation point.

[0046] This improvement method is highly scientific. The generation of bubbles is often due to the formation of local pressure differences, turbulence or dead corners on the surface of the workpiece. These environmental conditions are the main reasons for the generation of bubbles. At the bubble bursting point, the flow of the quenching liquid is more uniform or a fluid dynamic environment is formed that is conducive to the dissipation of bubbles. Therefore, with the help of the study of the bursting point, the injection angle, pressure and flow rate are optimized to a state close to the bursting point, which can effectively suppress the generation of bubbles. This fluid optimization method guided by the analysis of the dynamic behavior of bubbles ensures a more uniform cooling effect during the quenching process, reduces the conditions for bubble generation, and thus improves process efficiency.

[0047] In terms of feasibility, this method relies on advanced computer vision and data analysis technology to monitor the generation and collapse positions of bubbles in real time and accurately calculate the corresponding injection parameters. With the widespread use of high-resolution cameras, sensors and automatic control systems, the accuracy of adjusting the injection angle, pressure and flow rate has reached a level that can be optimized in real time. Therefore, implementing this bubble suppression strategy in a data-driven manner is not only technically feasible, but also can be flexibly applied to quenching tanks of various sizes and production processes. This method based on fluid dynamic optimization can be widely used in industrial production, thereby improving workpiece quality and reducing bubble-related production defects.

[0048] Furthermore, the method for optimizing the process of adding quenching liquid for steel wire sorbitization further comprises the following steps: Step S400, observe and record the injection effect of the modified second quenching liquid injection port, focus on analyzing whether the number of bubbles at the bubble generation point is reduced, if the number of bubbles is not reduced, continue to adjust the initial injection port to add optimization data, and repeatedly apply it to the second quenching liquid injection port.

[0049] Specifically, Figure 6 A flow chart is shown for adjusting the initial injection port addition optimization data and repeatedly applying it to the second quenching liquid injection port.

[0050] Among them, observing and recording the injection effect of the modified second quenching liquid injection port, focusing on analyzing whether the number of bubbles at the bubble generation point is reduced, if the number of bubbles is not reduced, continue to adjust the initial injection port to add optimization data, and repeatedly apply it to the second quenching liquid injection port. Specifically, the following steps are included: Step S401, observing and recording the injection effect of the modified second quenching liquid injection port, focusing on analyzing whether the number of bubbles at the bubble generation point is reduced; Step S402, if the number of bubbles has not decreased, selecting the second most stable point in the injection angle curve, injection pressure curve and injection flow curve as the new injection angle, injection pressure and injection flow, respectively; Step S403, applying the new injection angle, injection pressure and injection flow rate to the second quenching liquid injection port, and continuing to observe the change in the number of bubbles. If the bubbles still do not decrease significantly, further select the third stable point in the curve for subsequent optimization and adjustment until the number of bubbles reaches the ideal level.

[0051] In an embodiment of the present invention, analyzing whether the number of bubbles at the bubble generation point has decreased can be achieved by combining a real-time monitoring system with computer vision technology. This technology can capture the generation, movement and collapse of bubbles during the quenching process, and analyze and compare these data, especially the number and generation frequency of bubbles before and after the injection parameters are modified. If it is found through comparative observation that the generation frequency of bubbles is reduced and the number is reduced, it means that the adjustment of the injection parameters is effective. If the bubbles still maintain high-frequency generation, it indicates that further optimization is needed.

[0052] When the number of bubbles has not decreased significantly, the next step is to select the second most stable point of change from the curve of injection angle, pressure and flow rate as the new parameter. A stable point in the curve usually means that the parameter fluctuates less under different conditions and can maintain system stability. By selecting the second most stable point for adjustment, the injection conditions can be further optimized while ensuring the smooth flow of the quenching liquid, and possible bubble suppression points can be found. This process relies on the relationship between fluid dynamics and bubble generation, and stable parameter adjustments are used to avoid excessive turbulence of the fluid from causing bubbles.

[0053] After applying the new injection angle, pressure and flow rate, continue to observe the changes in the number of bubbles. If the number of bubbles still does not decrease significantly, it is necessary to further select the third stable point in the curve for fine adjustment. The deeper stable points in the curve may represent a more suitable operating range. By gradually adjusting these points, minor adverse fluid conditions can be eliminated and the generation of bubbles can be reduced. This step-by-step optimization method can ensure the stability of the quenching process, ultimately achieving the purpose of reducing or eliminating bubbles, thereby improving the cooling effect and production quality of the workpiece.

[0054] Furthermore, Figure 7 The application architecture diagram of the system provided by the embodiment of the present invention is shown.

[0055] Among them, in another preferred embodiment provided by the present invention, a steel wire sorbitization quenching liquid addition process optimization system comprises: The bubble flow path determination module 100 is used to obtain real-time quenching liquid adding process video data of the target quenching tank, and determine multiple bubble flow paths according to the real-time quenching liquid adding process video data.

[0056] Specifically, Figure 8 The structure block diagram of the bubble flow path determination module 100 in the system provided by the embodiment of the present invention is shown.

[0057] Among them, in the preferred embodiment provided by the present invention, the bubble flow path determination module 100 specifically includes: The video data acquisition unit 101 is used to acquire the real-time quenching liquid adding process video data of the target quenching tank; The video data analysis unit 102 is used to intelligently analyze the real-time quenching liquid addition process video data based on computer vision technology, and determine the bubble generation position, movement trajectory and burst position; The bubble flow path generating unit 103 is used to generate a bubble flow path from the generation to the collapse of the bubble according to the generation position, movement trajectory and collapse position of the bubble.

[0058] In an embodiment of the present invention, obtaining real-time video data of the quenching liquid addition process requires installing a high-resolution industrial camera or a high-speed camera at a key position of the quenching tank. These cameras should have properties such as high temperature resistance and waterproofness, and be able to capture the flow of the quenching liquid and the formation, movement, and collapse of bubbles during the quenching process. The camera is connected to a computer system, and the video data is transmitted to the computer in real time for subsequent analysis. In this way, the flow of the quenching liquid can be recorded in real time and used for subsequent processing.

[0059] To intelligently analyze video data based on computer vision technology, the real-time quenching video must first be preprocessed. Common image processing techniques such as denoising, grayscale processing, and contrast enhancement can improve the clarity of the image and highlight the characteristics of the bubbles. In the processed image, the presence of bubbles is identified by edge detection algorithms (such as the Sobel operator) or convolutional neural networks (CNN). Next, the target tracking algorithm (such as optical flow or Kalman filtering) is used to track the movement trajectory of each bubble, and the entire process from bubble generation to disappearance can be accurately recorded.

[0060] As the bubbles move and change position, the computer vision system can analyze the bubble generation location, movement path, and burst location in real time. The system determines the bubble life cycle by the changes in bubble size and shape, and generates a complete bubble flow path diagram. These data are displayed through visualization tools to help engineers optimize quenching liquid injection parameters and improve bubble problems during quenching. This process realizes automated bubble monitoring and path analysis, which can be applied and adjusted in real time during actual production.

[0061] Furthermore, the steel wire sorbitization quenching liquid addition process optimization system also includes: The initial injection port addition optimization data generation module 200 is used to determine the bubble generation point and the bubble bursting point of each bubble flow path, and obtain the injection related data of the first quenching liquid injection port closest to each bubble bursting point, and integrate the injection related data of multiple first quenching liquid injection ports to generate the initial injection port addition optimization data, wherein the injection related data includes the injection angle, injection pressure and injection flow rate.

[0062] Specifically, Fig. 9 It shows a structural block diagram of the initial injection port addition optimization data generation module 200 in the system provided by an embodiment of the present invention.

[0063] Among them, in the preferred embodiment provided by the present invention, the initial injection port addition optimization data generation module 200 specifically includes: A bubble point determination unit 201, for determining a bubble generation point and a bubble collapse point of each bubble flow path according to a bubble generation position and a bubble collapse position in each bubble flow path; The liquid injection related data acquisition unit 202 is used to determine the first quenching liquid injection port closest to each bubble burst point, and acquire the liquid injection related data of the first quenching liquid injection port corresponding to each bubble burst point; The liquid injection related data integration unit 203 is used to generate initial injection port addition optimization data according to the liquid injection related data of multiple first quenching liquid injection ports.

[0064] In an embodiment of the present invention, in order to determine the first quenching liquid injection port closest to each bubble burst point, it is first necessary to accurately locate the bubble burst position by computer vision technology. These position information will be recorded in the form of coordinates and reflected in the three-dimensional space of the quenching tank. Subsequently, the position of each bubble burst point is compared with the coordinates of all quenching liquid injection ports in the quenching tank, and the distance between the bubble burst point and each injection port is calculated. The shortest distance between the bubble burst point and the injection port is calculated by a distance formula (such as Euclidean distance), and finally the quenching liquid injection port closest to each other is selected as the associated injection port of the bubble burst point.

[0065] Once the injection port closest to the bubble bursting point is found, the injection data of the injection port (including injection angle, pressure and flow rate, etc.) can be further analyzed to optimize the flow of the quenching liquid, burst the bubbles as quickly as possible and reduce the generation of new bubbles.

[0066] The target quenching tank is usually equipped with multiple quenching liquid injection ports, which are evenly distributed at different positions in the quenching tank to ensure that the quenching liquid can cover the entire surface of the steel wire or workpiece. During the design process, the arrangement of the injection ports usually takes into account the size of the workpiece, the flow path of the quenching liquid, and the cooling efficiency. For example, the injection ports can be arranged symmetrically along both sides of the quenching tank, or distributed at different heights and angles to minimize local uneven cooling and bubble accumulation. Different injection ports work independently through an intelligent control system, and the injection parameters (such as angle, pressure, flow rate, etc.) can be dynamically adjusted according to the distribution of bubble generation to ensure that the bubbles are effectively controlled and the workpiece is cooled evenly during the entire quenching process.

[0067] Selecting the point with the most stable curve change and the best corresponding effect as the optimal injection angle, pressure and flow rate can significantly reduce the generation of bubbles. During the quenching process, the formation of bubbles often leads to uneven cooling, which affects the quality of the workpiece. By determining the optimal injection parameters, the quenching liquid can cover the surface of the workpiece in a more uniform manner, reducing turbulence and bubble generation caused by excessive local flow rate. The optimal injection angle can ensure that the contact between the flow direction of the quenching liquid and the workpiece surface is more stable, avoiding turbulence; the optimal injection pressure can maintain the appropriate injection intensity to prevent the increase of bubbles caused by excessive pressure; and the optimal flow rate ensures uniform coverage of the liquid and reduces local siltation and bubble retention.

[0068] By reducing the generation of bubbles, the entire quenching process becomes more stable and efficient. The reduction of bubbles means that the quenching liquid can fully contact the surface of the workpiece, thereby achieving a more uniform cooling effect and avoiding local over-high or over-low temperatures. In addition, reducing bubbles also helps to reduce the surface defect rate of the workpiece and improve the mechanical properties of the product.

[0069] This optimization based on scientific data, through experiments and analysis, finds the most stable and effective points in each parameter curve, which can further improve the repeatability and stability of the process. In each quenching operation, the injection angle, pressure and flow rate can be kept consistent, so as to maintain a uniform cooling effect in different batches of production and ensure the reliability of product quality.

[0070] Finally, by reducing the generation of bubbles, the energy consumption of the entire quenching process is also optimized. Reducing unnecessary bubble generation and collapse can reduce the flow resistance of the quenching liquid, making the cooling process more efficient and thus reducing energy consumption. This optimization not only improves production efficiency, but also brings cost savings to the company.

[0071] Furthermore, the steel wire sorbitization quenching liquid addition process optimization system also includes: The injection related data modification module 300 is used to obtain the injection related data of the second quenching liquid injection ports that are closest to different bubble generation points, and modify the injection related data of each second quenching liquid injection port according to the initial injection port addition optimization data.

[0072] In an embodiment of the present invention, first, it is necessary to monitor the location of bubble generation in the quenching tank in real time through video data or computer vision technology, and accurately record the coordinates of these bubble generation points. Then, the coordinates of these bubble generation points are matched with the coordinates of each second quenching liquid injection port in the quenching tank, and the distance between each bubble generation point and all quenching liquid injection ports is calculated. The Euclidean distance formula is usually used to calculate the spatial distance between these points. By comparing these distances, the system can quickly identify the second quenching liquid injection port closest to the bubble generation point, ensuring that the quenching liquid can reach the bubble generation area by the shortest path, further optimizing the cooling effect.

[0073] By modifying the injection angle, injection pressure and injection flow rate of the second quenching liquid injection port corresponding to the bubble generation point to the optimal parameters, this improved method can effectively eliminate the bubbles originally generated near the bubble generation point. The principle is based on using the bubble collapse point as a reference to "replace" the original bubble generation point by optimizing the injection method. This method utilizes the fluid dynamic environment of the bubble collapse point, that is, the flow characteristics of the quenching liquid in the collapse point area contribute to the natural dissipation of bubbles. By adjusting the injection conditions at the generation point to be similar to the injection conditions at the collapse point, the flow state of the fluid will be optimized, thereby preventing bubbles from forming at the generation point.

[0074] This improvement method is highly scientific. The generation of bubbles is often due to the formation of local pressure differences, turbulence or dead corners on the surface of the workpiece. These environmental conditions are the main reasons for the generation of bubbles. At the bubble bursting point, the flow of the quenching liquid is more uniform or a fluid dynamic environment is formed that is conducive to the dissipation of bubbles. Therefore, with the help of the study of the bursting point, the injection angle, pressure and flow rate are optimized to a state close to the bursting point, which can effectively suppress the generation of bubbles. This fluid optimization method guided by the analysis of the dynamic behavior of bubbles ensures a more uniform cooling effect during the quenching process, reduces the conditions for bubble generation, and thus improves process efficiency.

[0075] In terms of feasibility, this method relies on advanced computer vision and data analysis technology to monitor the generation and collapse positions of bubbles in real time and accurately calculate the corresponding injection parameters. With the widespread use of high-resolution cameras, sensors and automatic control systems, the accuracy of adjusting the injection angle, pressure and flow rate has reached a level that can be optimized in real time. Therefore, implementing this bubble suppression strategy in a data-driven manner is not only technically feasible, but also can be flexibly applied to quenching tanks of various sizes and production processes. This method based on fluid dynamic optimization can be widely used in industrial production, thereby improving workpiece quality and reducing bubble-related production defects.

[0076] Furthermore, the steel wire sorbitization quenching liquid addition process optimization system also includes: The initial injection port addition optimization data adjustment module 400 is used to observe and record the injection effect of the modified second quenching liquid injection port, focusing on analyzing whether the number of bubbles at the bubble generation point has decreased. If the number of bubbles has not decreased, continue to adjust the initial injection port addition optimization data and repeatedly apply it to the second quenching liquid injection port.

[0077] In an embodiment of the present invention, analyzing whether the number of bubbles at the bubble generation point has decreased can be achieved by combining a real-time monitoring system with computer vision technology. This technology can capture the generation, movement and collapse of bubbles during the quenching process, and analyze and compare these data, especially the number and generation frequency of bubbles before and after the injection parameters are modified. If it is found through comparative observation that the generation frequency of bubbles is reduced and the number is reduced, it means that the adjustment of the injection parameters is effective. If the bubbles still maintain high-frequency generation, it indicates that further optimization is needed.

[0078] When the number of bubbles has not decreased significantly, the next step is to select the second most stable point of change from the curve of injection angle, pressure and flow rate as the new parameter. A stable point in the curve usually means that the parameter fluctuates less under different conditions and can maintain system stability. By selecting the second most stable point for adjustment, the injection conditions can be further optimized while ensuring the smooth flow of the quenching liquid, and possible bubble suppression points can be found. This process relies on the relationship between fluid dynamics and bubble generation, and stable parameter adjustments are used to avoid excessive turbulence of the fluid from causing bubbles.

[0079] After applying the new injection angle, pressure and flow rate, continue to observe the changes in the number of bubbles. If the number of bubbles still does not decrease significantly, it is necessary to further select the third stable point in the curve for fine adjustment. The deeper stable points in the curve may represent a more suitable operating range. By gradually adjusting these points, minor adverse fluid conditions can be eliminated and the generation of bubbles can be reduced. This step-by-step optimization method can ensure the stability of the quenching process, ultimately achieving the purpose of reducing or eliminating bubbles, thereby improving the cooling effect and production quality of the workpiece.

[0080] It should be understood that, although each step in the flow chart of each embodiment of the present invention is shown in sequence according to the indication of the arrow, these steps are not necessarily performed in sequence according to the order indicated by the arrow. Unless there is a clear explanation in this article, the execution of these steps does not have a strict order restriction, and these steps can be performed in other orders. Moreover, at least a portion of the steps in each embodiment may include a plurality of sub-steps or a plurality of stages, and these sub-steps or stages are not necessarily performed at the same time, but can be performed at different times, and the execution order of these sub-steps or stages is not necessarily performed in sequence, but can be performed in turn or alternately with at least a portion of other steps or sub-steps or stages of other steps.

[0081] Those skilled in the art can understand that all or part of the processes in the above-mentioned embodiment methods can be completed by instructing the relevant hardware through a computer program, and the program can be stored in a non-volatile computer-readable storage medium. When the program is executed, it can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to memory, storage, database or other media used in the embodiments provided in this application may include non-volatile and / or volatile memory. Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM) or flash memory. Volatile memory may include random access memory (RAM) or external cache memory. As an illustration and not limitation, RAM is available in many forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link (Synchlink) DRAM (SLDRAM), memory bus (Rambus) direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM).

[0082] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0083] The above-mentioned embodiments only express several implementation methods of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the scope of the patent of the present invention. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

[0084] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for optimizing the process of adding quenching liquid for steel wire sorbitization, characterized in that: The method comprises: Acquire real-time quenching liquid adding process video data of the target quenching tank, and determine multiple bubble flow paths according to the real-time quenching liquid adding process video data; Determine the bubble generation point and bubble bursting point of each bubble flow path, and obtain the injection-related data of the first quenching liquid injection port closest to each bubble bursting point, and generate initial injection port addition optimization data based on the injection-related data of multiple first quenching liquid injection ports; Acquire the injection related data of the second quenching liquid injection ports that are closest to different bubble generation points, and modify the injection related data of each second quenching liquid injection port according to the initial injection port addition optimization data; Observe and record the injection effect of the modified second quenching liquid injection port, and focus on analyzing whether the number of bubbles at the bubble generation point has decreased. If the number of bubbles has not decreased, continue to adjust the initial injection port to add optimization data, and repeatedly apply it to the second quenching liquid injection port.

2. The method for optimizing the addition process of quenching liquid for steel wire sorbitization according to claim 1, characterized in that: The injection related data include injection angle, injection pressure and injection flow rate.

3. The method for optimizing the addition process of quenching liquid for steel wire sorbitization according to claim 1, characterized in that: The steps of obtaining real-time quenching liquid adding process video data of the target quenching tank, and determining multiple bubble flow paths according to the real-time quenching liquid adding process video data include: Acquire real-time quenching liquid adding process video data of the target quenching tank; Intelligently analyze the real-time quenching liquid addition process video data based on computer vision technology, and determine the bubble generation location, movement trajectory and bursting location; According to the generation position, movement trajectory and collapse position of the bubble, a bubble flow path from the generation to the collapse of the bubble is generated.

4. The method for optimizing the addition process of quenching liquid for steel wire sorbitization according to claim 3, characterized in that: The steps of determining the bubble generation point and the bubble collapse point of each bubble flow path, and obtaining the injection-related data of the first quenching liquid injection port closest to each bubble collapse point, and integrating the injection-related data of the plurality of first quenching liquid injection ports to generate the initial injection port addition optimization data include: Determine a bubble generation point and a bubble collapse point of each bubble flow path according to a bubble generation position and a bubble collapse position in each bubble flow path; Determine the first quenching liquid injection port closest to each bubble burst point, and obtain injection-related data of the first quenching liquid injection port corresponding to each bubble burst point; Initial injection port addition optimization data is generated based on the integration of injection-related data of multiple first quenching liquid injection ports.

5. The method for optimizing the addition process of quenching liquid for steel wire sorbitization according to claim 4, characterized in that: The step of integrating the injection-related data of the plurality of first quenching liquid injection ports to generate the initial injection port addition optimization data comprises: Acquire the injection angles, injection pressures and injection flow rates of the plurality of first quenching liquid injection ports, and generate an injection angle curve graph, an injection pressure curve graph and an injection flow curve graph respectively according to the plurality of injection angles, injection pressures and injection flow rates; From the injection angle curve, injection pressure curve and injection flow curve, select the point with the most stable curve change and the best corresponding effect as the optimal injection angle, optimal injection pressure and optimal injection flow respectively; The optimal injection angle, optimal injection pressure and optimal injection flow rate are integrated to obtain the initial injection port addition optimization data.

6. The method for optimizing the addition process of quenching liquid for steel wire sorbitization according to claim 5, characterized in that: The steps of obtaining injection-related data of the second quenching liquid injection ports that are closest to different bubble generation points, and modifying the injection-related data of each second quenching liquid injection port according to the initial injection port adding optimization data include: Determine the second quenching liquid injection port that is closest to different bubble generation points; Obtaining the injection angle, injection pressure and injection flow rate of the second quenching liquid injection port corresponding to different bubble generation points; The injection angle, injection pressure and injection flow rate of the second quenching liquid injection port corresponding to different bubble generation points are modified to the optimal injection angle, optimal injection pressure and optimal injection flow rate.

7. The method for optimizing the addition process of quenching liquid for steel wire sorbitization according to claim 6, characterized in that: The steps of observing and recording the injection effect of the modified second quenching liquid injection port, focusing on analyzing whether the number of bubbles at the bubble generation point is reduced, and if the number of bubbles is not reduced, continuing to adjust the initial injection port to add optimization data, and repeatedly applying it to the second quenching liquid injection port include: Observe and record the injection effect of the modified second quenching liquid injection port, and focus on analyzing whether the number of bubbles at the bubble generation point has been reduced; If the number of bubbles does not decrease, select the second most stable point in the injection angle curve, injection pressure curve, and injection flow rate curve as the new injection angle, injection pressure, and injection flow rate, respectively; Apply the new injection angle, injection pressure and injection flow rate to the second quenching liquid injection port, and continue to observe the changes in the number of bubbles. If the bubbles still do not decrease significantly, further select the third stable point in the curve for subsequent optimization and adjustment until the number of bubbles reaches the ideal level.

8. A system for optimizing the process of adding quenching liquid for steel wire sorbitization, characterized in that: The system comprises: a bubble flow path determination module, an initial injection port addition optimization data generation module, an injection related data modification module and an initial injection port addition optimization data adjustment module, wherein: A bubble flow path determination module is used to obtain real-time quenching liquid addition process video data of a target quenching tank, and determine multiple bubble flow paths according to the real-time quenching liquid addition process video data; An initial injection port addition optimization data generation module is used to determine the bubble generation point and the bubble bursting point of each bubble flow path, and obtain the injection related data of the first quenching liquid injection port closest to each bubble bursting point, and generate the initial injection port addition optimization data according to the injection related data of multiple first quenching liquid injection ports, wherein the injection related data includes the injection angle, the injection pressure and the injection flow rate; A liquid injection related data modification module, used to obtain liquid injection related data of the second quenching liquid injection ports that are closest to different bubble generation points, and modify the liquid injection related data of each second quenching liquid injection port according to the initial injection port addition optimization data; The initial injection port adds an optimization data adjustment module, which is used to observe and record the injection effect of the modified second quenching liquid injection port, focusing on analyzing whether the number of bubbles at the bubble generation point has decreased. If the number of bubbles has not decreased, continue to adjust the initial injection port to add optimization data, and repeatedly apply it to the second quenching liquid injection port.

9. The steel wire sorbitization quenching liquid addition process optimization system according to claim 8, characterized in that: The bubble flow path determination module specifically includes: A video data acquisition unit, used to acquire real-time quenching liquid addition process video data of a target quenching tank; A video data analysis unit, which is used to intelligently analyze the real-time quenching liquid addition process video data based on computer vision technology, and determine the bubble generation location, movement trajectory and bursting location; The bubble flow path generating unit is used to generate a bubble flow path from the generation to the collapse of the bubble according to the generation position, movement trajectory and collapse position of the bubble.

10. The steel wire sorbitization quenching liquid addition process optimization system according to claim 9, characterized in that: The initial injection port addition optimization data generation module specifically includes: a bubble point determination unit, for determining a bubble generation point and a bubble collapse point of each bubble flow path according to a bubble generation position and a bubble collapse position in each bubble flow path; A liquid injection related data acquisition unit, used to determine the first quenching liquid injection port closest to each bubble burst point, and acquire liquid injection related data of the first quenching liquid injection port corresponding to each bubble burst point; The liquid injection related data integration unit is used to generate initial injection port addition optimization data based on the liquid injection related data of multiple first quenching liquid injection ports.

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