Water cooling air conditioner water route pressurization and automatic regulation system for PCB dust-free workshop

Abstract

The application discloses a water-cooled air conditioner water route pressurization and automatic regulation system for a PCB dust-free workshop, which comprises a water-cooled circulation pressurization module, a multi-mode adaptive control unit, an electromagnetic valve partition regulation component, a double-redundancy safety protection system, an electronic pressure switch connected in parallel with a mechanical safety valve, and an intelligent compensation algorithm module; and the pressure set value and PID control parameters are dynamically corrected in combination with the ambient temperature, water conductivity and water-cooled equipment heat dissipation efficiency. The system cooperatively constructs a full-closed loop water-cooled control system through multiple modules; the water-cooled circulation pressurization module adjusts the water pressure in real time through a variable frequency water pump set; the multi-mode adaptive control unit is connected to an MES system, pre-adjusts the equipment state and switches the constant pressure / energy saving / emergency mode; and the electromagnetic valve partition regulation component adopts a combination of a dynamic balance valve, an electromagnetic valve and a sensor, realizes stable flow and meets the PCB production requirements.

Description

Technical Field

[0001] This invention belongs to the field of water-cooled air conditioning water circuit pressurization and regulation technology for cleanrooms, and particularly relates to a water-cooled air conditioning water circuit pressurization and automatic regulation system for PCB board cleanrooms. Background Technology

[0002] In water-cooled air conditioning systems in PCB cleanrooms, the piping network typically needs to be divided into multiple independent zones (such as exposure machine zone, etching machine zone, cleaning zone, etc.), with each zone's cooling water flow controlled by a solenoid valve. However, traditional solutions have two major problems:

[0003] Inter-regional coupling interference: When a solenoid valve in a certain region is opened or closed, it will change the water resistance of the entire pipe network, causing water pressure fluctuations in other regions, which in turn affects the stability of flow. For example, closing a valve in region A may cause a sudden increase or decrease in flow in region B.

[0004] Uncontrolled flow distribution: Even if the same pressure is set in each area, the actual flow rate may deviate by more than ±20% due to differences in pipe length, number of bends, etc., which cannot meet the stringent requirements of temperature and humidity control in PCB production. For example, the cooling water flow rate of the exposure machine needs to fluctuate by ≤±3%. Summary of the Invention

[0005] The purpose of this invention is to address the problem that current water-cooled air conditioning systems in PCB cleanrooms typically require dividing the pipe network into multiple independent zones and controlling the flow of cooling water through solenoid valves. However, this results in problems such as coupling interference between zones and uncontrolled flow distribution, which fail to meet the needs of PCB production. Therefore, this invention proposes a water-cooled air conditioning system for pressurizing and automatically regulating water circuits in PCB cleanrooms.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a water-cooled air conditioning system for pressurization and automatic adjustment in a PCB board cleanroom, comprising:

[0007] Water-cooled circulation booster module; integrates variable frequency water pump set, pressure sensor and flow meter, monitors water pressure and flow in real time, and dynamically adjusts water pump speed through frequency converter to maintain constant water pressure;

[0008] Multi-mode adaptive control unit; automatically switches between constant pressure mode, energy-saving mode and emergency mode according to the production load of the cleanroom. In the emergency mode, when a water leak is detected, the backup pump is started and the solenoid valve in the faulty area is closed.

[0009] Solenoid valve zone control component: Divides the water-cooled air conditioning network into multiple independent circulation zones. Each zone is equipped with a normally closed solenoid valve and a temperature and humidity sensor to independently adjust the cooling water flow based on the temperature and humidity deviation of the zone.

[0010] Dual-redundant safety protection system; electronic pressure switch and mechanical safety valve are connected in parallel, and if either detects overpressure, the water pump will stop and the pressure relief branch will be opened;

[0011] It also includes an intelligent compensation algorithm module; combining ambient temperature, water conductivity, and the heat dissipation efficiency of water-cooled equipment, it dynamically corrects the pressure setpoint and PID control parameters to compensate for system deviations caused by changes in water quality or equipment aging.

[0012] As a further description of the above technical solution:

[0013] The multi-mode adaptive control unit includes:

[0014] Production load prediction submodule: By accessing the workshop MES system to obtain equipment operation plans, the pump speed and solenoid valve status are pre-adjusted 10-30 minutes in advance to avoid pressure fluctuations affecting PCB production accuracy;

[0015] Energy-saving optimization strategy: Automatically switch to energy-saving mode during low-load periods at night, reduce the set pressure to the minimum demand value and close solenoid valves in unnecessary areas;

[0016] Fault self-recovery function: When a brief pressure abnormality is detected, the water pump is automatically restarted. If the abnormality persists, the fault is locked and an alarm is pushed to the operation and maintenance terminal.

[0017] As a further description of the above technical solution:

[0018] The solenoid valve zone control component includes:

[0019] Dynamic balancing valve integration; a dynamic balancing valve is connected in series before each solenoid valve. The dynamic balancing valve is used to adjust and eliminate coupling interference between zones, ensuring that the cooling water flow in each zone is independent and stable.

[0020] Solenoid valve life management unit: records the number of times each solenoid valve is opened and closed and the cumulative on / off time, prioritizes the use of solenoid valves with longer remaining lifespan, and generates maintenance reminders.

[0021] As a further description of the above technical solution:

[0022] The dual-redundant security protection system includes:

[0023] Protection submodule: A liquid level sensor is installed at the water pump inlet. When a water shortage is detected, the power supply to the water pump and all solenoid valves are cut off simultaneously to prevent the pump body from running dry and being damaged.

[0024] Electrical isolation circuit: Optical isolators are used to physically separate the solenoid valve drive circuit from the control motherboard to avoid malfunctions caused by electromagnetic interference.

[0025] As a further description of the above technical solution:

[0026] Also includes:

[0027] Online water quality monitoring module: Real-time detection of cooling water quality via conductivity and pH sensors. When water quality exceeds the standard, the drain valve is automatically opened and new water is added. At the same time, the pressure setpoint is adjusted to compensate for the impact of water quality changes on heat dissipation efficiency.

[0028] Remote operation and maintenance management platform; uploads system operation data to the cloud server via 4G / 5G or industrial Ethernet, supporting real-time viewing of pressure curves, equipment status, and remote parameter modification on PC and mobile devices.

[0029] As a further description of the above technical solution:

[0030] The MES system is equipped with a data interface module, which is used to acquire equipment power, running time and production schedule in real time; it is linked with the workshop temperature and humidity control system to prioritize the stability of water cooling supply in high-precision process areas.

[0031] As a further description of the above technical solution:

[0032] The water quality exceeding the standard is determined by the following rules: when the conductivity is >1500μS / cm or the pH is <6.5 / >8.5, sewage discharge is triggered; if the standard is exceeded for 3 consecutive times, the machine will be forcibly shut down and the system will be locked, requiring manual reset and restart; during the sewage discharge process, the water pump speed will be automatically reduced to 30% of the rated value to avoid water flow impact causing pipeline leakage.

[0033] As a further description of the above technical solution:

[0034] It also includes: an abnormality warning module; when the pressure deviates from the set value by ±10% for more than 15 minutes, or the solenoid valve failure rate exceeds twice per month, it will automatically send an SMS / email to the administrator.

[0035] And a firmware remote upgrade interface module; update the control program via cloud push, fix algorithm vulnerabilities or add new functions without on-site downtime maintenance.

[0036] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0037] 1. In this invention, the PCB board cleanroom water-cooled air conditioning water circuit pressurization and automatic adjustment system achieves high-precision and high-reliability water-cooling control through multi-module collaboration: the water-cooled circulation pressurization module uses a variable frequency water pump group as the core, combined with real-time monitoring data from pressure / flow sensors, to dynamically adjust the water pump speed to maintain constant water pressure; the multi-mode adaptive control unit is connected to the workshop MES system, pre-adjusts the equipment status 10-30 minutes in advance based on production load prediction, and supports constant pressure / energy saving / emergency mode switching; in case of leakage, the backup pump is started and the fault area is isolated; the solenoid valve zoning control component divides the pipeline network into independent areas, and each area achieves pressure-independent flow stability control and solenoid valve life balance management through a combination of "dynamic balance valve + solenoid valve + temperature and humidity sensor"; the dual-redundant safety protection system adopts a parallel design of electronic pressure switch and mechanical safety valve. The system integrates dry-run protection (water shortage shutdown) and electrical isolation (electromagnetic interference prevention) to ensure inherent safety under abnormal conditions such as overpressure / water shortage. The intelligent compensation algorithm module integrates ambient temperature, water conductivity, and equipment heat dissipation efficiency parameters to dynamically correct pressure setpoints and PID control parameters, compensating for system deviations caused by water quality deterioration or equipment aging. The online water quality monitoring module detects water quality in real time through conductivity / pH sensors, automatically discharging wastewater and compensating for pressure when levels exceed standards, and forcibly shutting down the system if levels exceed standards continuously. The remote operation and maintenance management platform supports cloud data storage and multi-terminal access, providing abnormal early warning (such as continuous pressure deviation of ±10%), remote firmware upgrades, and equipment status visualization functions, forming a fully closed-loop control system of perception-decision-execution-optimization, comprehensively meeting the high precision, high stability, and low maintenance cost requirements of PCB cleanrooms for water cooling systems.

[0038] 2. This invention constructs a fully closed-loop water-cooling control system through multi-module collaboration: the water-cooling circulation booster module adjusts the water pressure in real time using a variable frequency water pump set; the multi-mode adaptive control unit is connected to the MES system to pre-adjust equipment status and switch between constant pressure / energy-saving / emergency modes; the solenoid valve zone control component adopts a combination of "dynamic balance valve + solenoid valve + sensor" to achieve stable flow and balanced lifespan; the dual-redundant safety protection system integrates overpressure protection, dry-run shutdown, and electrical isolation to ensure inherent safety; the intelligent compensation algorithm dynamically corrects parameters, and the online water quality monitoring module automatically discharges sewage and compensates for pressure deviations; the remote operation and maintenance platform supports cloud monitoring and early warning, forming a "perception-decision-execution-optimization" closed loop, fully meeting the high precision, high stability, and low maintenance requirements of PCB workshops.

[0039] 3. This invention constructs a dual-layer protection system of "mechanical self-balancing + electromagnetic control" by connecting a pressure-independent regulating valve (dynamic balancing valve) in series before the solenoid valve, which fundamentally solves the flow coupling problem of multi-zone water cooling systems and provides a reliable solution for high-precision temperature control scenarios such as PCB cleanrooms. Attached Figure Description

[0040] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 This is a working framework diagram of a water-cooled air conditioning system for pressurizing and automatically regulating water circuits in a cleanroom for PCB boards. Detailed Implementation

[0042] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0043] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0044] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0045] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0046] In the description of the embodiments of the present invention, it should be noted that the terms "upper" and "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the present invention.

[0047] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0048] Please see Figure 1 This invention provides a technical solution: a water-cooled air conditioning system for pressurization and automatic adjustment in a PCB board cleanroom, comprising:

[0049] Water-cooled circulation booster module; integrates variable frequency water pump set, pressure sensor and flow meter, monitors water pressure and flow in real time, and dynamically adjusts water pump speed through frequency converter to maintain constant water pressure;

[0050] Multi-mode adaptive control unit; automatically switches between constant pressure mode, energy-saving mode and emergency mode according to the cleanroom production load (such as equipment start-up and shutdown, personnel density). In the emergency mode, when a water leak is detected, the backup pump is started and the solenoid valve in the fault area is closed.

[0051] Solenoid valve zone control component: Divides the water-cooled air conditioning network into multiple independent circulation zones. Each zone is equipped with a normally closed solenoid valve and a temperature and humidity sensor to independently adjust the cooling water flow based on the temperature and humidity deviation of the zone.

[0052] Dual redundancy safety protection system; electronic pressure switch and mechanical safety valve are connected in parallel. When either one detects overpressure (e.g., ≥1.2MPa), it triggers the water pump to stop and opens the pressure relief branch.

[0053] It also includes an intelligent compensation algorithm module; combining ambient temperature, water conductivity, and the heat dissipation efficiency of water-cooled equipment, it dynamically corrects the pressure setpoint and PID control parameters to compensate for system deviations caused by changes in water quality or equipment aging.

[0054] The multi-mode adaptive control unit includes:

[0055] Production load prediction submodule: By accessing the workshop MES system to obtain equipment operation plans, the pump speed and solenoid valve status are pre-adjusted 10-30 minutes in advance to avoid pressure fluctuations affecting PCB production accuracy;

[0056] Energy-saving optimization strategy: Automatically switch to energy-saving mode during low-load periods at night, reduce the set pressure to the minimum demand value (e.g., 0.4MPa) and close solenoid valves in unnecessary areas;

[0057] Fault self-recovery function: When a brief pressure abnormality is detected (e.g., ≤5 seconds), the water pump is automatically restarted. If the abnormality persists, the fault is locked and an alarm is pushed to the operation and maintenance terminal.

[0058] The solenoid valve zone control component includes:

[0059] Dynamic balancing valve integration; a dynamic balancing valve is connected in series before each solenoid valve. The dynamic balancing valve is used to adjust and eliminate coupling interference between zones, ensuring that the cooling water flow in each zone is independent and stable.

[0060] Solenoid valve life management unit: records the number of times each solenoid valve is opened and closed and the cumulative on / off time, prioritizes the use of solenoid valves with longer remaining lifespan, and generates maintenance reminders.

[0061] The dual-redundant security protection system includes:

[0062] Protection submodule: A liquid level sensor is installed at the water pump inlet. When a water shortage is detected, the power supply to the water pump and all solenoid valves are cut off simultaneously to prevent the pump body from running dry and being damaged.

[0063] Electrical isolation circuit: Optical isolators are used to physically separate the solenoid valve drive circuit (24V DC) from the control main board (5VDC) to avoid malfunctions caused by electromagnetic interference.

[0064] Also includes:

[0065] Online water quality monitoring module: Real-time detection of cooling water quality via conductivity and pH sensors. When water quality exceeds the standard, the drain valve is automatically opened and new water is added. At the same time, the pressure setpoint is adjusted to compensate for the impact of water quality changes on heat dissipation efficiency.

[0066] Remote operation and maintenance management platform; uploads system operation data to the cloud server via 4G / 5G or industrial Ethernet, supporting real-time viewing of pressure curves, equipment status, and remote parameter modification on PC and mobile devices.

[0067] The MES system is equipped with a data interface module, which is used to acquire equipment power, running time and production schedule in real time; it is linked with the workshop temperature and humidity control system to prioritize the stability of water cooling supply in high-precision process areas (such as exposure machines and etching machines).

[0068] The data interface module is also equipped with a prediction unit, which can predict the trend of water cooling demand changes within the next hour with an error rate of ≤5%.

[0069] The water quality exceeding the standard is determined by the following rules: when the conductivity is >1500μS / cm or the pH is <6.5 / >8.5, sewage discharge is triggered; if the standard is exceeded for 3 consecutive times, the machine will be forcibly shut down and the system will be locked, requiring manual reset and restart; during the sewage discharge process, the water pump speed will be automatically reduced to 30% of the rated value to avoid water flow impact causing pipeline leakage.

[0070] It also includes: an abnormality warning module; when the pressure deviates from the set value by ±10% for more than 15 minutes, or the solenoid valve failure rate exceeds twice per month, it will automatically send an SMS / email to the administrator.

[0071] And a firmware remote upgrade interface module; update the control program via cloud push, fix algorithm vulnerabilities or add new functions without on-site downtime maintenance.

[0072] Working Principle: This PCB board cleanroom water-cooled air conditioning system achieves high-precision and high-reliability water-cooling control through multi-module collaboration: The water-cooled circulation booster module uses a variable frequency water pump set as its core, combined with real-time monitoring data from pressure / flow sensors, to dynamically adjust the pump speed to maintain constant water pressure; The multi-mode adaptive control unit is connected to the workshop MES system, pre-adjusting equipment status 10-30 minutes in advance based on production load prediction, and supports switching between constant pressure / energy-saving / emergency modes. In case of leakage, a backup pump is activated and the faulty area is isolated; The solenoid valve zoning control component divides the pipeline network into independent areas. Each area uses a combination of "dynamic balancing valve + solenoid valve + temperature and humidity sensor" to achieve pressure-independent flow stability control and balanced solenoid valve lifespan management; The dual-redundant safety protection system adopts a parallel design of electronic pressure switches and mechanical safety valves. The system integrates dry-run protection (water shortage shutdown) and electrical isolation (electromagnetic interference protection) to ensure inherent safety under abnormal conditions such as overpressure / water shortage. The intelligent compensation algorithm module integrates ambient temperature, water conductivity, and equipment heat dissipation efficiency parameters to dynamically correct pressure setpoints and PID control parameters, compensating for system deviations caused by water quality deterioration or equipment aging. The online water quality monitoring module detects water quality in real time through conductivity / pH sensors, automatically discharging wastewater and compensating for pressure when levels exceed standards, and forcibly shutting down the system if levels exceed standards continuously. The remote operation and maintenance management platform supports cloud data storage and multi-terminal access, providing abnormal early warning (such as continuous pressure deviation of ±10%), remote firmware upgrades, and equipment status visualization functions, forming a fully closed-loop control system of perception-decision-execution-optimization, comprehensively meeting the high precision, high stability, and low maintenance cost requirements of PCB cleanrooms for water cooling systems.

[0073] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A water-cooled air conditioning system for pressurization and automatic adjustment in a PCB board cleanroom, characterized in that, include: Water-cooled circulation booster module; integrates variable frequency water pump set, pressure sensor and flow meter, monitors water pressure and flow in real time, and dynamically adjusts water pump speed through frequency converter to maintain constant water pressure; Multi-mode adaptive control unit; automatically switches between constant pressure mode, energy-saving mode and emergency mode according to the production load of the cleanroom. In the emergency mode, when a water leak is detected, the backup pump is started and the solenoid valve in the faulty area is closed. Solenoid valve zone control component: Divides the water-cooled air conditioning network into multiple independent circulation zones. Each zone is equipped with a normally closed solenoid valve and a temperature and humidity sensor to independently adjust the cooling water flow based on the temperature and humidity deviation of the zone. Dual-redundant safety protection system; electronic pressure switch and mechanical safety valve are connected in parallel, and if either detects overpressure, the water pump will stop and the pressure relief branch will be opened; Intelligent compensation algorithm module: Combining ambient temperature, water conductivity and heat dissipation efficiency of water cooling equipment, dynamically corrects pressure setpoint and PID control parameters to compensate for system deviations caused by water quality changes or equipment aging. Online water quality monitoring module: Real-time detection of cooling water quality via conductivity and pH sensors. When water quality exceeds the standard, the drain valve is automatically opened and new water is added. At the same time, the pressure setpoint is adjusted to compensate for the impact of water quality changes on heat dissipation efficiency. And a remote operation and maintenance management platform; upload system operation data to the cloud server via 4G / 5G or industrial Ethernet, and support real-time viewing of pressure curves, equipment status and remote parameter modification on PC and mobile devices; The water quality exceeding the standard is determined by the following rules: when the conductivity is >1500μS / cm or the pH is <6.5 / >8.5, sewage discharge is triggered; if the standard is exceeded for 3 consecutive times, the machine will be forcibly shut down and the system will be locked, requiring manual reset and restart; during the sewage discharge process, the water pump speed will be automatically reduced to 30% of the rated value to avoid water flow impact causing pipeline leakage.

2. The water-cooled air conditioning system for cleanrooms of PCB boards according to claim 1, characterized in that, The multi-mode adaptive control unit includes: Production load prediction submodule: By accessing the workshop MES system to obtain equipment operation plans, the pump speed and solenoid valve status are pre-adjusted 10-30 minutes in advance to avoid pressure fluctuations affecting PCB production accuracy; Energy-saving optimization strategy: Automatically switch to energy-saving mode during low-load periods at night, reduce the set pressure to the minimum demand value and close solenoid valves in unnecessary areas; Fault self-recovery function: When a brief pressure abnormality is detected, the water pump is automatically restarted. If the abnormality persists, the fault is locked and an alarm is pushed to the operation and maintenance terminal.

3. The water-cooled air conditioning system for cleanrooms of PCB boards according to claim 1, characterized in that, The solenoid valve zone control component includes: Dynamic balancing valve integration; a dynamic balancing valve is connected in series before each solenoid valve. The dynamic balancing valve is used to adjust and eliminate coupling interference between zones, ensuring that the cooling water flow in each zone is independent and stable. Solenoid valve life management unit: records the number of times each solenoid valve is opened and closed and the cumulative on / off time, prioritizes the use of solenoid valves with longer remaining lifespan, and generates maintenance reminders.

4. The water-cooled air conditioning water circuit pressurization and automatic adjustment system for a PCB board cleanroom according to claim 1, characterized in that, The dual-redundant security protection system includes: Protection submodule: A liquid level sensor is installed at the water pump inlet. When a water shortage is detected, the power supply to the water pump and all solenoid valves are cut off simultaneously to prevent the pump body from running dry and being damaged. Electrical isolation circuit: Optical isolators are used to physically separate the solenoid valve drive circuit from the control motherboard to avoid malfunctions caused by electromagnetic interference.

5. The water-cooled air conditioning system for cleanrooms of PCB boards according to claim 2, characterized in that, The MES system is equipped with a data interface module, which is used to acquire equipment power, running time and production schedule in real time; it is linked with the workshop temperature and humidity control system to prioritize the stability of water cooling supply in high-precision process areas.

6. The water-cooled air conditioning system for cleanrooms of PCB boards according to claim 1, characterized in that, Also includes: Anomaly warning module; when the pressure deviates from the set value by ±10% for more than 15 minutes, If the solenoid valve failure rate exceeds twice per month, an SMS / email will be automatically sent to the administrator. And a firmware remote upgrade interface module; update the control program via cloud push, fix algorithm vulnerabilities or add new functions without on-site downtime maintenance.

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