Pressing wheel surface treatment quality control system and method

Abstract

The invention discloses a pressing wheel surface treatment quality control system and method, and belongs to the technical field of automation. The system comprises a heating furnace module used for providing a treatment space for surface treatment of the pressing and pasting wheel; the temperature control module is used for heating the treatment space and controlling the temperature; the high-temperature atmosphere module is used for inputting a corresponding atmosphere into the treatment space according to the high-temperature atmosphere type requirement and the atmosphere flow requirement; the low-temperature atmosphere module is used for inputting a corresponding atmosphere into the treatment space according to the low-temperature atmosphere type requirement and the atmosphere flow requirement; the additive module is used for inputting corresponding additives into the treatment space according to the treatment process requirements; the upper computer is connected with the temperature control module, the high-temperature atmosphere module, the low-temperature atmosphere module and the additive module, and is used for receiving real-time data of the corresponding modules and controlling the work of each module; and the upper computer is used for receiving the real-time data of the corresponding modules and controlling the work of each module.

Description

Technical Field

[0001] The present invention belongs to the field of automation technology, and particularly relates to a quality control system and method for the surface treatment of a pressing wheel. Background Art

[0002] At present, various large-scale wooden utensils (such as various cabinets, desks, various beds, etc.) are processed by automatic processing equipment. Various large-scale automatic processing equipment is required. The world's annual market demand for such automatic processing equipment is huge, and there are not many enterprises in China that can produce such automatic processing equipment. The produced automatic processing equipment is used in the domestic market on the one hand and exported to the international market on the other hand, and there is currently a situation of fierce competition with foreign enterprises. Among such automatic processing equipment, one of the most important components is pressing wheels of various different models.

[0003] Although the pressing wheel is small, various index requirements are strict. It not only requires a high surface hardness (HV>550), but also requires a high anti-corrosion performance. At the same time, the fit tolerance is strict (in the micron range), and deformation must be controlled during the processing. In addition, the surface color is required to be uniform and beautiful. To meet these requirements, the current domestic treatment method is to grind after electroplating chromium to meet the quality requirements. As is well known, electroplating belongs to a heavy pollution technology. Before electroplating chromium, pretreatment such as pickling and alkali washing must be carried out. Trivalent chromium in the electroplating solution is a carcinogenic substance. At present, the country has strict requirements for environmental protection. Some small electroplating enterprises have been closed, and large electroplating enterprises must carry out strict post-treatment of waste liquid before discharging, so the production cost has been greatly increased. The hardness and anti-corrosion performance of the pressing wheel depend on the thickness of the electroplating layer. To reduce costs, many enterprises control the thickness at the lower limit, resulting in the anti-corrosion performance not meeting the requirements of the salt spray test standard in many cases. At the same time, the surface size will exceed the standard after electroplating chromium, and subsequent grinding processing must be carried out, further increasing the cost. It seriously affects the competitiveness of Chinese enterprises in the international market. Summary of the Invention

[0004] The present invention aims to solve at least one of the technical problems in the above related technologies to some extent.

[0005] For this reason, the purpose of the present invention is to provide a quality control system and method for the surface treatment of a pressing wheel, which realizes the purposes of pollution-free, low-cost, and high-quality without any waste liquid or waste discharged during the production process.

[0006] In order to solve the above technical problems, the present invention is implemented as follows: The embodiment of the present invention provides a quality control system for the surface treatment of a pressing wheel, and the system includes: A heating furnace module for providing a treatment space for the surface treatment of the pressing wheel; The temperature control module, connected to the heating furnace module, is used to heat the processing space and control the temperature; The high-temperature atmosphere module, connected to the processing space, is used to input corresponding atmosphere into the processing space according to the requirements of high-temperature atmosphere type and atmosphere flow rate; The low-temperature atmosphere module, connected to the processing space, is used to input corresponding atmosphere into the processing space according to the requirements of low-temperature atmosphere type and atmosphere flow rate; The additive module, connected to the processing space, is used to input corresponding additives into the processing space according to the requirements of the processing technology; The upper computer is connected to the temperature control module, the high-temperature atmosphere module, the low-temperature atmosphere module and the additive module, and is used to receive the real-time data of the corresponding modules and control the operation of each module; The upper computer is connected to the temperature control module, the high-temperature atmosphere module, the low-temperature atmosphere module, and the additive module, and is used to receive the real-time data of the corresponding modules and control the operation of each module.

[0007] In addition, the pressure bonding wheel surface treatment quality control system according to the present invention may further have the following additional technical features: In some embodiments, the heating furnace module includes a heating furnace, a top cover, an exhaust assembly, an inlet pipe, a stirring fan and a furnace pot; The furnace pot is arranged inside the heating furnace; the top cover is arranged on the top of the furnace pot, and the inlet pipe and the exhaust assembly are arranged on the top cover to realize adding atmosphere into the furnace pot and exhausting the redundant atmosphere; The stirring fan is fixedly arranged on the top cover; The pressure bonding wheel workpiece to be processed and the bracket required for surface treatment are arranged inside the furnace pot.

[0008] In some embodiments, the temperature control module includes a heating wire, a thermocouple and an electrical control cabinet, and the electrical control cabinet includes an intelligent thermometer and a solid-state relay; The thermometer, the solid-state relay and the heating wire are connected in sequence, and the heating wire is wound around the outer circumference of the furnace pot or the inner circumference of the heating furnace; the thermometer controls the on-off of the solid-state relay to control the heating operation of the heating wire; The thermocouple is arranged on the furnace pot and connected to the thermometer to measure the real-time temperature of the heating furnace and transmit it to the thermometer; the thermometer controls the solid-state relay according to the received real-time temperature.

[0009] In some embodiments, the high-temperature atmosphere module includes ammonia gas cylinders, nitrogen gas cylinders, carbon dioxide gas cylinders, natural gas cylinders, and flow meters and valves matching each gas cylinder; Each valve is an electrically controlled valve and is connected to the host computer, capable of being opened and closed under the control of the host computer; each flowmeter is connected to the host computer, capable of transmitting real-time flow measurement data to the host computer for processing and analysis; Each gas cylinder is connected to the intake pipe of the heating furnace module through an atmosphere pipeline, capable of inputting the corresponding atmosphere into the processing space through the atmosphere pipeline and the intake pipe.

[0010] In some embodiments, the low-temperature atmosphere module includes ammonia gas cylinders, oxygen gas cylinders, and flowmeters and valves matching each gas cylinder; Each valve is an electrically controlled valve and is connected to the host computer, capable of being opened and closed under the control of the host computer; each flowmeter is connected to the host computer, capable of transmitting real-time flow measurement data to the host computer for processing and analysis; Each gas cylinder is connected to the intake pipe of the heating furnace module through an atmosphere pipeline, capable of inputting the corresponding atmosphere into the processing space through the atmosphere pipeline and the intake pipe.

[0011] In some embodiments, the additive module includes an additive bottle and a micro pump. The additive bottle is connected to the intake pipe of the heating furnace module through an additive pipeline. The micro pump is arranged on the additive pipeline and is capable of extracting the additive in the additive bottle and inputting it into the processing space.

[0012] The embodiment of the present invention also provides a method for controlling the surface treatment quality of a pressing wheel. The method is implemented by the surface treatment quality control system of the pressing wheel as described in any one of the above. The control method includes: A process configuration process for selecting a process and revising parameters through a host computer to determine the optimal process for the current pressing wheel to be processed; A production implementation process for performing surface treatment on the pressing wheel according to the determined optimal process; A process optimization process for optimizing each existing process according to the data of the process configuration process and / or the data of the production implementation process and storing it in the process database.

[0013] In addition, according to the method for controlling the surface treatment quality of the pressing wheel of the present invention, the following additional technical features may also be provided: In some embodiments, the steps of the process configuration process include: S101. Enter the process configuration page of the host computer; S102. Select the material model, specification, size, and / or performance requirements of the product to be processed; S103. Read the existing process information, recommend several processes according to user requirements and historical production big data, and display them on the process page; S104. The user clicks to view the detailed data of the process; S105. The user selects a process from the displayed processes for the workpiece to be processed; S106. Enter the process adjustment step, ask whether to adjust the process details, and the user can choose yes or no; if yes, enter the step of adjusting the process details and end the process configuration process; if no, end the process configuration process; The specific content of the process detail adjustment step includes: manually adjusting the process parameters through the host computer; then judging whether the adjusted process flow is a new standard process. If it is judged to be yes, create a new standard process and store the corresponding data in the standard process database; if it is judged to be no, update the data of the current standard process according to the adjusted process parameters and save it.

[0014] In some of the embodiments, the steps of the production implementation process include: S201. Select a production task and start it; S202. The industrial control software system judges whether data anomalies occur; if so, enter the next step, otherwise continue the production task and record the production data of this time into the database after the production task ends; S203. Give an early warning to prompt the process or data with data anomalies; S204. The user views the warning information and data; S205. Judge whether the abnormal data needs to be processed. If so, enter the next step, otherwise continue the production task and record the production data of this time into the database after the production task ends; S206. Pause the production task, check the abnormal process, and revise it; record the abnormal data into the database; S207. Select whether to restart. If so, return to S201, otherwise end this production process.

[0015] In some of the embodiments, the steps of the process optimization process include: S301. Implement the selected optimized process; S302. Read various monitoring data during the production process of the optimized process, conduct physical and chemical tests on various indicators required by the product to obtain test data; at the same time, conduct data processing, integration and analysis to obtain the law existing between the process parameters and the test indicators; The monitoring data includes temperature, pressure, flow rate, product surface area and product surface roughness; S303. Compare the obtained product inspection index data with the index data required for the product. If the obtained data meets or exceeds the required index data, it is considered that the selected optimized process has achieved the optimization goal. If the obtained data does not meet the required index data, modify the process parameters according to the relationship between the process parameters and the inspection indexes obtained in S302 to obtain a re-optimized process. Implement the entire process of S301 - S303 again until the product index data produced by the finally obtained optimized process meets the required index data.

[0016] Compared with the prior art, the present invention has at least the following beneficial effects: In the embodiment of the present invention, the provided surface treatment quality control system for the pressing wheel uses a new type of gas multi-element co-permeation technology to replace the electroplating chromium technology, without any waste liquid or waste discharged during the production process, achieving the purpose of pollution-free, low-cost, and high-quality production. In the embodiment of the present invention, for the provided surface treatment quality control system for the pressing wheel, compared with electroplating chromium, the low-temperature gas multi-element co-permeation technology does not require subsequent grinding processing, and the cost is reduced by about 60%. In practice, it is found that by using different process parameters for different models of pressing wheels, the cost can be further reduced. In the embodiment of the present invention, for the provided surface treatment quality control system for the pressing wheel, by recording parameters and summarizing through multiple batches of production, the relationship between process parameters and different indexes of the product is established. As the number of production batches increases, the process parameters are continuously optimized, and the optimal surface treatment process can be provided for a specific model of pressing wheel. In the embodiment of the present invention, for the provided surface treatment quality control system for the pressing wheel, it can flexibly adjust the process detail parameters of this wheel according to the actual situation, and can also automatically simulate whether the adjusted process meets the production standards (such as corrosion resistance), and create a new standard process when necessary to ensure the scientificity and personalization of process selection. In the embodiment of the present invention, for the provided surface treatment quality control system for the pressing wheel, it realizes the comprehensive real-time data monitoring of the production process, which is essentially different from the ex-post data analysis in the prior art: 1) It can real-time monitor key parameters such as temperature, flow rate, and pressure, and immediately issue a warning when an abnormality occurs, prompting the user to check and process, and can automatically pause the production task according to the abnormal data, guide the user to revise the abnormal process, and record the abnormal data for subsequent analysis; 2) It can dynamically adjust the working parameters of each module (such as temperature rise and fall control, air flow control) through real-time data to ensure that the production process is always in the best state; 3) This real-time monitoring and intelligent processing mechanism effectively avoids product quality problems caused by unprocessed abnormal data during the production process, ensuring the continuity and stability of production.

[0017] The quality control method for the surface treatment of the pressing wheel in the present invention is implemented by using the described quality control system for the surface treatment of the pressing wheel. Therefore, it has at least all the features and advantages of the quality control system for the surface treatment of the pressing wheel, which will not be elaborated here. The additional aspects and advantages of the present invention will be partially given in the following description, partially become obvious from the following description, or be understood through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic structural diagram of the quality control system for the surface treatment of the pressing wheel disclosed in an embodiment of the present invention; Figure 2 It is a process configuration flowchart of the upper computer in an embodiment of the present invention; Figure 3 It is a production implementation flowchart disclosed in an embodiment of the present invention; Figure 4 It is a data simulation and process optimization flowchart disclosed in an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0019] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without making creative efforts shall fall within the protection scope of the present invention.

[0020] Next, the embodiments of the present invention will be described in detail in conjunction with the accompanying drawings through specific embodiments and their application scenarios.

[0021] Based on the problems of the prior art, the present invention has developed a new gas multi-element co-permeation technology to replace the electroplating chromium technology. This technology has no waste liquid or waste discharged during the production process, achieving the goals of pollution-free, low-cost, and high-quality. There is no precedent at home and abroad for using this new surface treatment method for the pressing wheel, and the following problems have been found in practice: 1) Unstable product quality: Using the same process parameters, sometimes the products meet the quality requirements, while sometimes the unqualified rate of the products is very high; 2) The problem of further reducing costs: Compared with electroplating chromium, using the low-temperature gas multi-element co-permeation technology to treat the pressing wheel, the production cost is low, and the subsequent grinding processing cost is not required, reducing the cost by about 60%. However, it has been found in practice that different process parameters can be used for different models of pressing wheels to further reduce costs.

[0022] Solving the above problems involves the issue of adopting different processes for different models of pressure bonding wheels, that is, the problem of optimizing the process design for specific models of pressure bonding wheels. A large software system is used to obtain the optimized process. The specific technical route is as follows: 1) Record all kinds of parameters for each treatment of the pressure bonding wheel (such as temperature, time, ventilation volume, furnace loading, product surface area, materials used, roughness, etc.); 2) Detect various technical indicators of each furnace of products and record them all; 3) After summarizing multiple furnace runs, establish the relationship between process parameters and different indicators of the product (such as the relationship between the increase in temperature and the thickening of the surface compound layer, etc.). At the same time, for a specific model of pressure bonding wheel, obtain the better process parameters; as the number of production furnace runs increases, continuously optimize the process parameters and establish an ever-updating database; 4) When processing a new model of pressure bonding wheel, select a process with a similar size from the database for processing. After detecting the product quality, further optimize according to the relationship between the quality and the process parameters.

[0023] Based on this, please refer to Figure 1 As shown, in some embodiments of the present invention, a quality control system for the surface treatment of a pressure bonding wheel is provided. The system includes: a host computer, a heating furnace module, a temperature control module, a high-temperature atmosphere module, a low-temperature atmosphere module, and an additive module.

[0024] In some embodiments of the present invention, the heating furnace module includes a heating furnace, a furnace pot, a top cover, an exhaust assembly, an inlet pipe, and a stirring fan. The furnace pot is arranged inside the heating furnace, and the top cover is arranged on the top of the heating furnace and is hermetically connected to the top of the furnace pot. The inlet pipe and the exhaust assembly are arranged on the top cover to realize the addition of atmosphere into the furnace pot and the exclusion of excess atmosphere. The stirring fan is fixedly arranged on the top cover. The heating workpiece and the required bracket are arranged inside the furnace pot. Before processing, the pressure bonding wheel is placed in the furnace pot, the furnace door is closed, and then the required gas is introduced and heated to the required temperature; at this time, the gas in the furnace reacts with the pressure bonding wheel to generate active atoms, which penetrate into the surface to obtain an intermetallic compound layer and reach the required performance indicators.

[0025] In some embodiments of the present invention, the temperature control module includes a heating wire, a thermocouple, and an electrical control cabinet. The electrical control cabinet includes an intelligent thermometer and a solid-state relay. The heating wire is wound around the outer periphery of the furnace pot and the inner periphery of the heating furnace to heat the furnace pot and its internal space so that the temperature inside the furnace pot reaches the required temperature. The heating wire is connected to the solid-state relay and performs the heating operation under the action control of the solid-state relay. The thermocouple is arranged on the outer wall of the furnace pot to measure the real-time temperature of the furnace pot. The thermocouple is connected to the thermometer, and the real-time temperature measured by the thermocouple is transmitted to the thermometer. The thermometer controls the solid-state relay according to the real-time temperature and the preset temperature, controlling the on / off of the solid-state relay. The temperature control module is connected to the host computer, capable of transmitting data to the host computer for processing and analysis, and can also receive the control information and preset parameter data issued by the host computer.

[0026] In some embodiments of the present invention, the high-temperature atmosphere module includes ammonia gas cylinders, nitrogen gas cylinders, carbon dioxide gas cylinders, natural gas cylinders, and flow meters and valves matching each cylinder. Each valve is an electrically controlled valve and is connected to the host computer, capable of being opened and closed under the control of the host computer. Each flow meter is also connected to the host computer, capable of transmitting the real-time flow measurement data to the host computer for processing and analysis. Each gas cylinder is connected to the intake pipe through the atmosphere pipeline, capable of enabling the gas to enter the furnace pot through the atmosphere pipeline and the intake pipe to participate in the workpiece production and processing process.

[0027] In some embodiments of the present invention, the low-temperature atmosphere module includes oxygen gas cylinders, ammonia gas cylinders, and flow meters and valves matching each cylinder. Each valve is an electrically controlled valve and is connected to the host computer, capable of being opened and closed under the control of the host computer. Each flow meter is also connected to the host computer, capable of transmitting the real-time flow measurement data to the host computer for processing and analysis. Each gas cylinder is connected to the intake pipe through the atmosphere pipeline, capable of enabling the gas to enter the furnace pot through the atmosphere pipeline and the intake pipe to participate in the workpiece production and processing process.

[0028] In some embodiments of the present invention, the additive module includes an additive bottle and a micro pump. The additive bottle is connected to the intake pipe through the additive pipeline. The micro pump is arranged on the additive pipeline and can extract the additive in the additive bottle and input it into the furnace pot through the additive pipeline and the intake pipe to participate in the workpiece production and processing process.

[0029] The basic principle of gas multi-element co-permeation is that active atoms in the atmosphere penetrate into the surface of the pressing wheel to obtain an intermetallic compound layer, meeting the requirements of hardness and anti-corrosion performance. Therefore, it is required that the atmosphere distribution inside the furnace is uniform. A stirrer fan with adjustable speed is used to stir the gas. For pressing wheels of different models and loading amounts, different rotation speeds are used for stirring to ensure uniform atmosphere, thereby ensuring that the performance indicators of each pressing wheel are basically the same.

[0030] Through a large amount of experimental data, the present invention has learned that the factors closely related to high-quality pressing wheels include: processing temperature, processing time, ammonia gas flow rate, additive type, additive dosage, material composition, workpiece shape, workpiece surface condition, total workpiece weight, total workpiece surface area, and processing method, etc.

[0031] In the above embodiment, the temperature control method during the processing of the pressing wheel includes: First, formulate the heating temperature and time. The actual temperature of the furnace tank is collected by the thermocouple for temperature measurement and transmitted to the intelligent thermometer in the electrical control cabinet to obtain the specific temperature value at the current moment. The intelligent thermometer judges whether the temperature in the furnace reaches the specified requirements of the process, and according to the judgment result and the difference between the actual temperature value and the process requirement temperature value, controls the working state of the solid-state relay, so that it is energized or de-energized for a certain time to achieve the function of controlling the temperature. For example: If the temperature in the device is lower than the set temperature (that is, the process requirement temperature), the solid-state relay is in the on state to provide more energy to raise the temperature. If the temperature is higher than the specified value, the thermometer will transmit a signal to the solid-state relay to make the solid-state relay in the off state, cutting off the power supply to the device. By dissipating heat through the furnace body, the temperature of the heating furnace drops, so as to achieve the purpose of automatic adjustment. At the same time, the thermometer can transmit the temperature signal (including the specific temperature value and the time of measurement) to the computer to provide basic data for big data analysis. When the set time is reached, the computer transmits a signal to the instrument to automatically cut off the power, and the heating process ends.

[0032] In some embodiments of the present invention, the temperature setting range is 450 - 700 °C, which is specifically determined according to the technical requirements of different types of pressing wheels and the previous heat treatment process. The processing temperature should be lower than the tempering temperature of the previous quenching and tempering treatment of the pressing wheel. The calculation formula for controlling the processing time is: t = (0.3 ~ 0.45) * W In the formula, t is the processing time, with the unit of min; W is the workpiece mass, with the unit of kg. During operation, the heating temperature and processing time are determined according to the mass of the workpiece and the process requirements of the workpiece. The intelligent thermometer judges whether the temperature in the furnace reaches the specified requirements in the process. According to the actual temperature value in the device, the energizing and de-energizing time of the solid-state relay is adjusted to achieve the function of controlling the temperature.

[0033] In some embodiments of the present invention, the material composition is input into the big data analysis module, and the big data analysis module is embedded in the upper computer. Record the material composition of each different furnace batch. Before processing a batch of products, calculate the mass and surface area of the workpiece according to the shape, which are the basic data of the big data analysis module and also determine the processing time and the flow rate of the gas introduced. Similarly, by taking pictures, record the workpiece shape, surface condition and processing method (roughness, turning, grinding, etc.) and input them into the big data analysis module as the basic data for analysis.

[0034] In some embodiments of the present invention, the implementation of the atmosphere control method includes: Use high temperature gas control cabinet to introduce NH 3 、N 2 , CO 2 , natural gas. Specifically, after reaching the set temperature, open the valves of the ammonia cylinder, nitrogen cylinder, carbon dioxide cylinder and natural gas cylinder, and each cylinder enters the furnace tank through its own flow meter. At the same time, start the micro pump, and extract the additive from the additive tank through the micro pump and input it into the furnace tank. According to the specific performance requirements of the pressing wheel, the vortex flowmeter is used to control the gas flow that needs to enter the furnace tank. At the same time, the vortex flowmeter transmits the flow signal to the host computer to provide basic data for big data analysis. The vortex flowmeter is equipped with an electric regulating valve, which can adjust the flow value according to the set flow. For example: when the flow exceeds the set value range, the main control module of the host computer transmits the signal to the electric regulating valve, and the valve is closed to reduce the flow; conversely, when the flow is less than the set value range, the main control module controls the valve to open to increase the flow. The micro pump can automatically adjust the flow and transmit the flow value to the host computer. The exhaust gas in the furnace tank is discharged through the exhaust pipe and then burned. The pressure in the co-infiltration furnace is always maintained at a positive pressure of 200 to 1200Pa. After processing, the pressing wheel is directly taken out of the oven and cooled in the air.

[0035] In some embodiments of the present invention, the additive is a mixture of methanol, acetone, formamide and alcohol.

[0036] In the above embodiment, the calculation formula for atmosphere control includes: Ammonia flow rate = (0.2~0.6)*F, where F is the surface area of ​​the workpiece in m 2 ; CO 2 Flow rate = ammonia flow rate * (0.03~0.06), Natural gas flow = ammonia flow * (0.01~0.04), Additive flow rate = ammonia flow rate * (0.1-0.15), Among them, ammonia flow, CO 2 The units of flow rate, natural gas flow rate and additive flow rate are all m 3 / h. The additive is a liquid penetrant. According to the test results, 1000ml of liquid additive can generate 1.5m 3 Calculate the gas intake.

[0037] In some embodiments of the present invention, the pressing wheel needs to be beautified to meet the customer's requirements for the aesthetic state of the pressing wheel surface, such as requiring the pressing wheel surface to have a uniform color. Therefore, the pressing wheel needs to be beautified and the pressed wheel after the above treatment is put into the furnace tank again.Figure 1 For the low-temperature gas control cabinet shown, nitrogen, oxygen and beautifying agent are introduced. The additive tank can be replaced with a beautifying agent tank, or the beautifying agent can be directly loaded into the additive tank. The heating temperature is 500 °C, and the heating time is 0.5 - 1.0 hour. The types and flow rates of the atmosphere introduced for the beautifying treatment are shown in Table 1.

[0038]

[0039] In the above embodiment, through the cumulative test data of nearly 100 furnaces, the process standards for general press-fit wheel products were analyzed. The parameters of the standard process include: Material composition: 20 steel, 45 steel, 60 steel Workpiece quality: 200 - 400 kg (If the furnace loading is too small, the cost will increase; if the furnace loading is too large, the product performance will be uneven) Workpiece surface quality requirements: roughness less than 0.6, surface finish turning or grinding, removing oil stains; Workpiece surface area: 5 - 9 m 2 Heating temperature: 520 - 540 °C Treatment time: 2.5 - 3.5 h Ammonia flow rate: 3.0 - 4.0 m 3 / h CO 2 Flow rate: 0.15 - 0.3 m 3 / h Natural gas flow rate: 0.04 - 0.20 m 3 / h Additive flow rate: 0.4 - 0.5 m 3 / h Input the parameters of the above standard process into the host computer to form the control items of the standard process. During the production process, the standard process can be directly clicked to realize the control of the production process. For workpieces with some special requirements, the process parameters need to be reset. After the current device starts production, after the on-site operator loads the furnace, the operator manually sets the parameters of each instrument through the host computer and then starts production. If the operator sets the instrument parameters incorrectly, resulting in unqualified production quality for a certain batch, the host computer can automatically select the standard process according to the result of unqualified quality, and then set the instrument parameters according to the standard process parameters for subsequent production. After the production starts, the host computer can dynamically adjust the control parameters of the instrument at a certain point according to the process deviation of the real-time monitoring value of the sensor at that point, so that the process value at that point tends to be normal.

[0040] For example: When the standard process stipulates that the furnace temperature reaches 550 °, the additive ventilation volume is 10 m 3, when the system detects the point temperature of 550° through the temperature sensor, it immediately detects whether the current ventilation volume meets the standard. If it does not meet the standard, it controls the on / off of the additive point and detects the current gas concentration, which can ensure that it reaches 10 m in a very short time. 3 .

[0041] In some embodiments of the present invention, as Figure 2 shown, the process configuration steps of the host computer (with an industrial control software system and a database module embedded in the host computer) include: Step 1: Start the industrial control software system and enter the process configuration page; Step 2: Select the material model / specification, size, performance requirements, etc. of the product to be processed; Step 3: The big data analysis module (that is, the database and algorithm software in the figure) reads the process information and recommends n processes according to the user requirements and historical production big data, and displays them on the process page of the industrial control software system; Step 4: The user clicks to view the detailed data of the process: display the four-dimensional parameters of a certain process, including 1) production process parameters: temperature, time, ventilation volume (introduced after the additive is vaporized), etc. in the process furnace; 2) applicable product parameters: material model, size, applicable scenario, etc.; 3) cost / performance parameters: performance range (including corrosion resistance, surface thickness, etc.) and cost calculation (energy consumption, additive consumption, etc.) obtained by simulating different products; 4) real production result parameters: the process of the same / similar products actually produced based on this process and the actual detection results; Step 5: The user selects a process for the workpiece to be processed; Step 6: Enter the process adjustment step, ask whether to adjust the process details, and the user can choose yes or no; choose yes, enter the step of adjusting the process details, and end the process configuration process; choose no, then end the process configuration process; The specific content of the process detail adjustment step includes: manually adjusting the process parameters through the host computer; then judging whether the adjusted process flow is a new standard process, which can be judged by the big data analysis module. When the judgment is yes, create a new standard process and store the corresponding data in the standard process database; when the judgment is no, update the data of the current standard process according to the adjusted process parameters and save it.

[0042] In some embodiments of the present invention, as Figure 3 shown, the steps of the production implementation process include: Step 1: Select a production task and start it; Step 2: The user clicks to view the production monitoring data; the production status data during the production process is displayed, including: 1) Temperature data: furnace temperature, heating power, etc.; 2) Flow rate data: ventilation volume of additives, gas flow rate, supply speed and flow volume of liquids, etc.; 3) Pressure data: pressure changes of gases, pressure changes of liquids, etc.; 4) Time data: production time, production cycle, production efficiency, time spent on each process step, etc.; 5) Energy consumption data: electricity consumption, gas consumption, additive consumption, etc. Step 3: Determine whether data anomalies occur; if so, proceed to the next step, otherwise continue the production task and record the production data of this time into the database after the production task ends. Step 4: Issue a warning to prompt the process or data with data anomalies. Step 5: The user views the warning information and data. Step 6: Determine whether the abnormal data needs to be processed; if so, proceed to the next step, otherwise continue the production task and record the production data of this time into the database after the production task ends. Step 7: Pause the production task, check the abnormal process, and revise it; the abnormal data can be recorded into the database. Step 8: Select whether to restart; if so, return to Step 1, otherwise end this production process.

[0043] In some embodiments of the present invention, as Figure 4 shown, the steps of data simulation and process optimization include: Step 1: Implement the selected optimized process. Step 2: Read various monitoring data during the production process of the optimized process, and conduct physical and chemical tests on various indicators required for the product to obtain test data; at the same time, perform data processing, integration, and analysis to obtain the laws existing between process parameters and test indicators. The monitoring data includes temperature, pressure, flow rate, product surface area, and product surface roughness. Step 3: Compare the obtained product test index data with the index data required for the product; if it reaches or exceeds the index data required for the product, it is considered that the selected optimized process has achieved the optimization purpose; if it does not reach the index data required for the product, modify the process parameters according to the laws existing between the process parameters and test indicators obtained in Step 2 to obtain a re-optimized process. Implement the entire process of Step 1 - Step 3 again until the product index data produced by the finally obtained optimized process reaches the index data required for the product.

[0044] The host computer of the present invention is connected to the network, and can export the production process data and production quality data of certain furnace batches as encrypted files, and send them to process experts by means of emails, etc. After receiving the files, the experts can view: 1) the point data such as the temperature curve, ammonia gas volume curve, additive curve, etc. recorded in real time during the production of this furnace batch; 2) the furnace loading information such as the workpiece shape, surface condition, total weight / total area, solder joint material / method, etc.; 3) all rust photos during the quality inspection test process. It can assist process experts to more efficiently locate production problems, give solutions, and is beneficial to further improving the standard process model.

[0045] The advantages of the technical solution of the present invention include: 1) Intelligent process configuration and personalized recommendation The host computer software system of the present invention has the functions of intelligent process configuration and personalized recommendation, which is essentially different from the operator's manual selection of processes in the prior art: - Through the embedded big data analysis module, the system can recommend the best process plan for this round of production according to the material model, specifications, dimensions and performance requirements of the product to be processed, combined with historical production big data and user needs; - Support the operator to flexibly adjust the process detail parameters of this round according to the actual situation. The system will automatically simulate whether the adjusted process meets the production standards (such as corrosion resistance, etc.), and create a new standard process when necessary to ensure the scientific nature and personalization of process selection.

[0046] 2) Real-time data monitoring and intelligent processing The host computer software system of the present invention realizes the comprehensive real-time data monitoring of the [production process], which is different from the [post-event data] analysis in the prior art: - The system can real-time monitor key parameters such as temperature, flow rate, pressure, etc., and immediately issue a warning when an abnormality occurs, prompting the user to check and process; - The system can dynamically adjust the working parameters of each module (such as: temperature rise and fall control, air flow control) through real-time data to ensure that the production process is always in the best state; - More importantly, the system has the ability of intelligent exception handling, which can automatically pause the production task according to the abnormal data, guide the user to revise the abnormal process, and record the abnormal data for subsequent analysis.

[0047] This real-time monitoring and intelligent processing mechanism effectively avoids product quality problems caused by unprocessed abnormal data during the production process, and ensures the continuity and stability of production.

[0048] 3) Data-driven closed-loop process optimization The process optimization process in the prior art relies on manual experience and a small amount of experimental data. However, the host computer software system of the present invention is based on the law existing in the relationship between the multi-element co-permeation process parameters and performance obtained in S302, and compiles software technology to achieve intelligent process optimization in a data-driven manner: - The system can import experimental data, monitoring data during the production process, and product inspection data, conduct in-depth data analysis and mining, discover the relationship between parameters and quality, and generate the latest process simulation data; - The operator can review and verify these latest process simulation data and initiate small-batch experimental production to ensure that the optimized process is more scientific and reasonable.

[0049] This closed-loop optimization mechanism not only improves product quality, but also reduces production costs and enhances the market competitiveness of the enterprise.

[0050] 4) Remote collaboration and expert intelligent support The host computer software system of the present invention supports exporting all production process data and product inspection data as encrypted files and automatically sending them to process experts in the form of emails, etc., which is a function not available in the prior art.

[0051] In addition, experts can view detailed production records and quality inspection results on the off-site mobile client to assist process experts in more efficiently locating production problems and providing solutions.

[0052] For the parts not described in detail in the present invention, reference can be made to the prior art in this field or the well-known technology to those skilled in the art, and no further elaboration will be made here.

[0053] The embodiments of the present invention have been described above in conjunction with the accompanying drawings. However, the present invention is not limited to the above specific embodiments. The above specific embodiments are merely illustrative and not restrictive. Under the inspiration of the present invention, those of ordinary skill in the art can also make many forms without departing from the purpose of the present invention and the scope protected by the claims, and all belong to the protection scope of the present invention.

Claims

1. A pressing wheel surface treatment quality control system, characterized in that: The system comprises: A heating furnace module is used to provide a processing space for the surface treatment of the pressing wheel; A temperature control module, connected to the heating furnace module, for heating the processing space and controlling the temperature; A high temperature atmosphere module is connected to the processing space and is used to input a corresponding atmosphere into the processing space according to the high temperature atmosphere type requirement and atmosphere flow requirement; A low-temperature atmosphere module is connected to the processing space and is used to input a corresponding atmosphere into the processing space according to the requirements of the type of low-temperature atmosphere and the requirements of the atmosphere flow rate; An additive module, connected to the processing space, for inputting corresponding additives into the processing space according to the processing process requirements; The host computer is connected to the temperature control module, the high temperature atmosphere module, the low temperature atmosphere module and the additive module, and is used to receive real-time data of the corresponding modules and control the operation of each module; The host computer is connected to the temperature control module, the high temperature atmosphere module, the low temperature atmosphere module and the additive module, and is used to receive real-time data of the corresponding modules and control the operation of each module.

2. The pressing wheel surface treatment quality control system according to claim 1, characterized in that: The heating furnace module comprises a heating furnace, a top cover, an exhaust assembly, an air inlet pipe, a stirring fan and a furnace tank; The furnace pot is arranged in the heating furnace; the top cover is arranged on the top of the furnace pot, and the air inlet pipe and the exhaust assembly are arranged on the top cover, so as to realize adding atmosphere into the furnace pot and exhausting excess atmosphere; The stirring fan is fixed on the top cover; The pressing wheel workpiece to be processed and the bracket required for surface treatment are arranged inside the furnace tank.

3. The pressing wheel surface treatment quality control system according to claim 1, characterized in that: The temperature control module includes a heating wire, a thermocouple and an electrical control cabinet, and the electrical control cabinet includes an intelligent temperature meter and a solid-state relay; The temperature meter, the solid-state relay and the heating wire are connected in sequence, and the heating wire is wound around the outer periphery of the furnace tank or the inner periphery of the heating furnace; the temperature meter controls the on and off of the solid-state relay to control the heating work of the heating wire; The thermocouple is arranged on the furnace tank and connected to the temperature meter to measure the real-time temperature of the heating furnace and transmit the temperature to the temperature meter; the temperature meter controls the solid-state relay according to the received real-time temperature.

4. The pressing wheel surface treatment quality control system according to claim 1, characterized in that: The high temperature atmosphere module includes an ammonia gas cylinder, a nitrogen gas cylinder, a carbon dioxide gas cylinder, a natural gas gas cylinder, and a flow meter and a valve matched with each gas cylinder; Each valve is an electrically controlled valve and is connected to the host computer and can be opened and closed under the control of the host computer; each flow meter is connected to the host computer and can transmit real-time flow measurement data to the host computer for processing and analysis; Each gas cylinder is connected to the air inlet pipe of the heating furnace module through an atmosphere pipeline, and can input the corresponding atmosphere into the processing space through the atmosphere pipeline and the air inlet pipe.

5. The pressing wheel surface treatment quality control system according to claim 1, characterized in that: The low temperature atmosphere module includes an ammonia gas cylinder, an oxygen gas cylinder, and flow meters and valves matched with each gas cylinder; Each valve is an electrically controlled valve and is connected to the host computer and can be opened and closed under the control of the host computer; each flow meter is connected to the host computer and can transmit real-time flow measurement data to the host computer for processing and analysis; Each gas cylinder is connected to the air inlet pipe of the heating furnace module through an atmosphere pipeline, and can input the corresponding atmosphere into the processing space through the atmosphere pipeline and the air inlet pipe.

6. The pressing wheel surface treatment quality control system according to claim 1, characterized in that: The additive module includes an additive bottle and a micro pump. The additive bottle is connected to the air inlet pipe of the heating furnace module through an additive pipeline. The micro pump is arranged on the additive pipeline and can extract the additive in the additive bottle and input it into the processing space.

7. A method for controlling the surface treatment quality of a pressing wheel, characterized in that: The method is implemented by the pressing wheel surface treatment quality control system according to any one of claims 1 to 6, and the control method comprises: The process configuration process is used to select the process and revise the parameters through the host computer to determine the optimal process for the pressing wheel to be processed; Production implementation process for surface treatment of the pressing wheel according to the determined optimal process; The process optimization process is used to optimize the existing processes according to the data of the process configuration process and / or the data of the production implementation process, and save them in the process database.

8. The method for controlling the surface treatment quality of a pressing wheel according to claim 7, characterized in that: The steps of the process configuration flow include: S101, enter the process configuration page of the host computer; S102. Select material model, specification, size and / or performance requirements of the product to be processed; S103, reading existing process information and recommending several processes according to user requirements and historical production big data, and displaying them on the process page; S104, the user clicks to view detailed data of the process; S105, the user selects a process for the workpiece to be processed from the displayed processes; S106, entering the process adjustment step, asking whether to adjust the process details, the user can choose yes or no; if yes is chosen, entering the process details adjustment step, and ending the process configuration process; if no is chosen, the process configuration process ends; The specific contents of the process detail adjustment steps include: manually adjusting the process parameters through the host computer; then judging whether the adjusted process flow is a new standard process. If it is judged to be yes, a new standard process is created and the corresponding data is stored in the standard process database; if it is judged to be no, the data of the current standard process is updated according to the adjusted process parameters and saved.

9. The method for controlling the surface treatment quality of a pressing wheel according to claim 7, characterized in that: The steps in the production implementation process include: S201, select a production task and start it; S202, the industrial control software system determines whether data anomalies occur; if so, proceed to the next step; otherwise, continue the production task, and record the production data in the database after the production task is completed; S203, issuing an early warning to indicate abnormal processes or data; S204, the user checks the warning information and data; S205, determine whether the abnormal data needs to be processed, if so, proceed to the next step, otherwise continue the production task, and record the production data in the database after the production task is completed; S206, suspend the production task, check the abnormal process, and revise it; the abnormal data is recorded in the database; S207, select whether to restart, if yes, return to S201, otherwise end this production process.

10. The method for controlling the surface treatment quality of a pressing wheel according to claim 7, characterized in that: The steps in the process optimization process include: S301, implementing the selected optimization process; S302, reading various monitoring data in the process of optimizing the production process, and performing physical and chemical tests on various indicators required by the product to obtain test data; at the same time, performing data processing, integration and analysis to obtain the rules between process parameters and test indicators; S303, comparing the obtained product test index data with the index data required by the product; if the index data required by the product is reached or exceeded, it is considered that the selected optimization process has achieved the purpose of optimization; if the index data required by the product is not reached, the process parameters are modified according to the rules between the process parameters and the test indexes obtained in S302 to obtain a re-optimized process; The whole process of S301-S303 is implemented again until the product index data produced by the optimized process is finally obtained and reaches the index data required by the product.

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