Sectional type current self-adaptive control method and system for bolt electrogalvanizing process

Abstract

The invention discloses a sectional type current self-adaptive control method and system for a bolt electrogalvanizing process, which are applied to a bolt electrogalvanizing production line and aim at optimizing the quality of a zinc coating through sectional type current self-adaptive control. The method comprises the following steps: acquiring a process parameter sequence in a bolt electrogalvanizing process, wherein the process parameter sequence comprises current intensity characteristics of each segmented electroplating bath and segmented electroplating time characteristics; calculating a current time matching degree according to the current intensity characteristics and the segmented electroplating time characteristics; determining a current adaptability score of the segmented electroplating process based on the current time matching degree; and when the current adaptability score is higher than a preset segmentation score threshold, adaptively adjusting the current parameter of each segmented electroplating bath according to the score deviation degree and a preset adjustment rule, and generating an optimized galvanization control result. Through sectional current control and self-adaptive adjustment, the thickness uniformity and the process stability of a zinc coating are ensured, the bolt electrogalvanizing quality is remarkably improved, and the method is suitable for industrial production requirements.

Description

Technical Field

[0001] This invention relates to the field of metal surface treatment technology, specifically to a segmented current adaptive control method and system for bolt electroplating zinc process, applicable to bolt electroplating zinc production lines. By dynamically monitoring and adaptively adjusting the current parameters of the segmented electroplating tank, the quality of the zinc plating layer and process stability can be optimized. Background Technology

[0002] Electroplating zinc for bolts is an important surface treatment technology in industrial manufacturing. By electrodepositing a zinc coating on the bolt surface, it significantly improves their corrosion resistance, wear resistance, and service life, and is widely used in the automotive, construction, and machinery manufacturing industries. Traditional bolt electroplating zinc processes typically employ a fixed current control strategy, treating all bolts using a single current intensity and electroplating time parameter. However, this uniform control method has significant limitations. Due to differences in bolt materials (such as steel grade and surface roughness), geometric dimensions (such as diameter and length), and the operating conditions of the electroplating tank (such as electrolyte concentration, temperature, and electrode distribution), fixed current control cannot meet the personalized needs of different process conditions. This leads to uneven zinc coating thickness, insufficient or excessive deposition in localized areas, and even quality defects such as scorching and pinholes, seriously affecting the performance and reliability of the bolts.

[0003] Furthermore, traditional electroplating zinc processes lack the ability to dynamically monitor and adjust key parameters in real time. In segmented electroplating processes, the current intensity and plating time of multiple plating tanks are often set independently, failing to fully consider the coordination of parameters between tanks. This results in significant differences in the quality of the zinc plating layer between different tank segments. For example, excessively high current intensity in one segment may lead to an overly thick plating layer, while insufficient current in adjacent tanks may result in an overly thin plating layer, affecting the uniformity and consistency of the overall zinc plating layer. Simultaneously, existing technologies typically lack adaptive adjustment mechanisms based on real-time process parameters, failing to effectively address dynamic factors such as changes in electrolyte state, power supply fluctuations, or batch differences in bolts. This not only reduces the stability of the zinc plating layer quality but also increases energy consumption, material waste, and production costs, making it difficult to meet the demands of high-precision, high-efficiency industrial production.

[0004] Therefore, in order to address the problems of single current control, insufficient coordination of segmented tanks, and lack of dynamic adaptive adjustment in traditional electroplating zinc processes, there is an urgent need to develop a method and system that can perform segmented current adaptive control based on real-time process parameters, so as to optimize the uniformity of zinc coating thickness, improve process stability and production efficiency, and thus meet the stringent requirements of modern industry for high-quality bolts. Summary of the Invention

[0005] The purpose of this invention is to provide a segmented adaptive current control method and system for bolt electroplating zinc processes, aiming to solve the problems of single current control, insufficient coordination between segmented electroplating tanks, and lack of dynamic adjustment capability in traditional electroplating zinc processes. By real-time monitoring of the current intensity characteristics and electroplating time characteristics of each segmented electroplating tank, the current-time matching degree is calculated and a current adaptability score is determined. Based on the score deviation, the current parameters of each segmented electroplating tank are adaptively adjusted to optimize the uniformity and consistency of the zinc coating thickness. This invention, through segmented current control and adaptive adjustment mechanisms, effectively addresses differences in bolt material, size, and electroplating tank conditions, improving zinc coating quality, reducing energy consumption and production costs, enhancing process stability and production efficiency, and meeting the needs of high-precision industrial production.

[0006] Specifically, applied to bolt electroplating production lines, the method optimizes the quality of the zinc plating layer through segmented current adaptive control, and includes: A sequence of process parameters for the electroplating zinc process of bolts is obtained, wherein the sequence of process parameters includes at least a set of current intensity characteristics and segmented electroplating time characteristics of the bolts in the segmented electroplating tanks; a current-time matching degree is calculated based on the current intensity characteristics and the segmented electroplating time characteristics; a current adaptability score for the segmented electroplating process is determined based on the current-time matching degree; when the current adaptability score is higher than a preset segmented score threshold, the current parameters of each segmented electroplating tank are adaptively adjusted according to a preset adjustment rule based on the deviation degree of the current adaptability score, thereby generating optimized zinc plating control results.

[0007] Furthermore, the step of obtaining the process parameter sequence in the bolt electroplating zinc process includes: controlling the electroplating equipment to record a first characteristic timestamp when the bolt enters the first segmented electroplating tank and starting to monitor the change in current intensity; controlling the electroplating equipment to record a second characteristic timestamp when the bolt leaves the first segmented electroplating tank and stopping the monitoring of the change in current intensity; calculating the first segmented electroplating time characteristic based on the first characteristic timestamp and the second characteristic timestamp; generating the current intensity characteristic of the first segmented electroplating tank based on the change in current intensity during the monitoring period; repeating the above steps to obtain the electroplating time characteristic and current intensity characteristic of other segmented electroplating tanks to form a complete process parameter sequence.

[0008] Further, the step of calculating the current-time matching degree based on the current intensity characteristics and the segmented electroplating time characteristics, and determining the current adaptability score of the segmented electroplating process based on the current-time matching degree, includes: comparing the current intensity characteristics of each segmented electroplating tank with the corresponding preset optimized current standard value to obtain a current deviation coefficient; comparing the segmented electroplating time characteristics of each segmented electroplating tank with the corresponding preset time standard value to obtain a time deviation coefficient; calculating the current-time matching degree based on the current deviation coefficient and the time deviation coefficient; and calculating the current adaptability score based on the current-time matching degree, wherein the formula for calculating the current adaptability score S is: in, The actual current intensity of the i-th segmented electroplating tank. To preset and optimize the current standard value, Let i be the actual electroplating time of the i-th segmented electroplating tank. The preset time standard value is n, which is the total number of segmented electroplating tanks. The formula reflects the uniformity of zinc plating layer deposition in each segmented electroplating tank.

[0009] Furthermore, the preset segmented control condition is that the current adaptability score is higher than the preset segmented score threshold. The step of adaptively adjusting the current parameters of each segmented electroplating tank according to the deviation of the current adaptability score and the preset adjustment rules includes: determining whether the current adaptability score is higher than the preset segmented score threshold; if it is higher, determining that the current parameters of the current segmented electroplating process need to be adjusted; calculating the current adjustment amount of each segmented electroplating tank, wherein the current adjustment amount is proportional to the current deviation coefficient of the segmented electroplating tank; synchronously adjusting the current parameters of each segmented electroplating tank according to the calculated current adjustment amount; re-monitoring the adjusted current intensity characteristics and segmented electroplating time characteristics to verify the adjustment effect.

[0010] Furthermore, the step of calculating the current adjustment amount of each segmented electroplating tank further includes: identifying the target segmented electroplating tank where the current deviation coefficient exceeds a preset deviation threshold; for the target segmented electroplating tank, determining the current adjustment direction based on the sign of its current deviation coefficient; calculating the basic adjustment amount based on the absolute value of the current deviation coefficient of the target segmented electroplating tank; and correcting the basic adjustment amount according to the influence of the current parameters of adjacent segmented electroplating tanks to obtain the final current adjustment amount.

[0011] Furthermore, the step of correcting the basic adjustment amount based on the influence of current parameters of adjacent segmented electroplating tanks includes: obtaining the current intensity characteristics of the preceding and following segmented electroplating tanks of the target segmented electroplating tank; calculating the current intensity difference between the target segmented electroplating tank and the adjacent segmented electroplating tanks; when the current intensity difference exceeds a preset continuity threshold, smoothing the basic adjustment amount; and using the corrected current adjustment amount as the final current adjustment amount of the target segmented electroplating tank.

[0012] After generating the optimized galvanizing control result, the present invention further includes: sending the optimized galvanizing control result to the control platform of the bolt electrogalvanizing production line; controlling the control platform to generate segmented current control commands based on the optimized galvanizing control result; sending the segmented current control commands to the current regulating devices of the corresponding segmented electroplating tanks; and monitoring the current changes of each segmented electroplating tank after executing the segmented current control commands.

[0013] Furthermore, the step of re-monitoring the adjusted current intensity characteristics and segmented electroplating time characteristics to verify the adjustment effect further includes: after the current parameters are adjusted, continuing to monitor the changes in current intensity and corresponding electroplating time of each segmented electroplating tank; recalculating the current adaptability score based on the adjusted monitoring data; comparing the recalculated current adaptability score with the preset segmented score threshold; and repeating the current parameter adjustment step until the control requirements are met when the recalculated current adaptability score is still higher than the preset segmented score threshold.

[0014] The process further includes a segmented electroplating process monitoring step: during each current parameter adjustment, the current value before adjustment, the adjustment amount, and the value after adjustment for each segmented electroplating tank are recorded in real time; a historical database of current parameter adjustments for segmented electroplating tanks is established, storing historical adjustment records and corresponding zinc plating quality results; based on the adjustment records in the historical database, the preset optimized current standard value and preset time standard value in the subsequent electroplating process are optimized; and the calculation benchmark for the current adaptability score is updated according to the optimized preset standard value.

[0015] This invention also provides a segmented current adaptive control system for bolt electroplating zinc process, applied to a bolt electroplating zinc production line, the system comprising: The data acquisition module is configured to acquire the process parameter sequence in the bolt electroplating zinc process, wherein the process parameter sequence includes at least a set of current intensity characteristics and segmented electroplating time characteristics of the bolt in the segmented electroplating tank; The data processing module is configured to calculate the current-time matching degree based on the current intensity characteristics and the segmented electroplating time characteristics, and to determine the current adaptability score of the segmented electroplating process based on the current-time matching degree. The current adjustment module is configured to adaptively adjust the current parameters of each segment of the electroplating tank according to a preset adjustment rule based on the degree of deviation of the current adaptability score when the current adaptability score is higher than the preset segment score threshold, thereby generating optimized zinc plating control results.

[0016] This invention provides a segmented current adaptive control method and system for bolt electroplating zinc processes. Compared to traditional electroplating zinc processes, it effectively solves the problems of single current control, insufficient coordination between segmented electroplating tanks, and lack of dynamic adjustment capability, significantly improving the quality and process stability of the zinc plating layer. Addressing the issues of uneven zinc plating layer thickness, insufficient or excessive local deposition, and even quality defects such as scorching and pinholes caused by fixed current control in traditional processes, this invention monitors the current intensity characteristics and electroplating time characteristics of each segmented electroplating tank in real time, calculates the current-time matching degree, and generates a current adaptability score. Based on the score deviation, it adaptively adjusts the current parameters of each segmented electroplating tank, effectively adapting to changes in bolt materials, sizes, and electroplating tank conditions, ensuring the uniformity and consistency of the zinc plating layer thickness. Regarding the problem of inconsistent zinc plating layer quality due to the lack of coordination between current and time parameters in traditional segmented electroplating processes, this invention smooths and corrects the current adjustment amount based on the influence of current intensity in adjacent segmented electroplating tanks, ensuring consistent zinc plating performance across each segmented electroplating tank, further improving the reliability of the overall zinc plating layer. To address the limitations of traditional processes in handling changes in electrolyte state, power supply fluctuations, or batch variations in bolts, this invention dynamically optimizes current parameters based on real-time monitoring data and historical adjustment records. Furthermore, it continuously optimizes preset standard values ​​by establishing a historical database of current parameter adjustments, enhancing the adaptability and stability of the process. Simultaneously, through precise adaptive current adjustment, this invention reduces material waste and excessive energy consumption caused by improper parameters, significantly lowering production costs, increasing production efficiency, and meeting the demands of high-precision industrial production for high-quality bolts. This provides modern industry with an efficient and reliable surface treatment technology. Attached Figure Description

[0017] Figure 1 A flowchart of a segmented current adaptive control method for bolt electroplating zinc process provided by the present invention; Figure 2 The flowchart for obtaining the process parameter sequence in the segmented current adaptive control method for bolt electroplating zinc process provided by the present invention is shown. Figure 3 A flowchart of the current parameter adjustment process in the segmented current adaptive control method for bolt electroplating zinc process provided by the present invention. Figure 4 A schematic diagram of the segmented current adaptive control system for the bolt electroplating zinc process provided by the present invention.

[0018] Figure label: A segmented current adaptive control system 100 for bolt electroplating zinc process; a data acquisition module 101; a data processing module 102; and a current adjustment module 103. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature; in the description of this application, unless otherwise stated, "multiple" means two or more.

[0021] To more clearly illustrate the technical solution of the present invention, the present invention will be described in detail below with reference to specific embodiments, but it should not be construed as a limitation on the scope of protection of the present invention.

[0022] This embodiment provides a segmented current adaptive control method for the electroplating zinc process of bolts, such as... Figure 1 As shown, this technology is applied to an industrialized bolt electroplating production line. By monitoring and adaptively adjusting the current parameters of the segmented electroplating tanks in real time, the quality of the zinc plating layer and the stability of the process are optimized.

[0023] Step S01: Obtain the process parameter sequence in the bolt electroplating zinc process, wherein the process parameter sequence includes at least a set of current intensity characteristics and segmented electroplating time characteristics of the bolt in the segmented electroplating tank.

[0024] Specifically, in the actual operation of the bolt electroplating production line, high-precision sensors and data acquisition systems are used to acquire process parameter sequences. The production line is equipped with multiple segmented electroplating tanks, each equipped with a current sensor and timer to monitor the current intensity and electroplating time of the bolts in real time during the electroplating process. Furthermore, the current sensors acquire current intensity data from each segmented electroplating tank at millisecond-level frequencies, generating current intensity characteristics reflecting current change trends, such as recording the average value, peak value, and fluctuation range of the current. Understandably, the timer records the time points when the bolts enter and leave each segmented electroplating tank, forming segmented electroplating time characteristics, including the electroplating duration of each tank. This data is transmitted to the central control unit via an industrial control network (such as the Modbus protocol), where it is aggregated into a process parameter sequence, providing basic data for subsequent analysis.

[0025] Step S02: Calculate the current-time matching degree based on the current intensity characteristics and the segmented electroplating time characteristics.

[0026] Specifically, after receiving the process parameter sequence, the central control unit uses an embedded algorithm to analyze the current intensity characteristics and segmented electroplating time characteristics to calculate the current-time matching degree. Further, the algorithm first compares the current intensity characteristics of each segmented electroplating tank with a preset optimized current standard value to assess whether the current is within the expected range. Simultaneously, it compares the segmented electroplating time characteristics with a preset time standard value to determine whether the electroplating time meets the process requirements. Understandably, the current-time matching degree, through a comprehensive evaluation of the comparison results, reflects the degree of coordination between current intensity and electroplating time. For example, if the current intensity of a certain segmented electroplating tank is too high while the electroplating time is too short, the matching degree will be low, indicating a need for adjustment to optimize zinc plating deposition.

[0027] Step S03: Determine the current adaptability score of the segmented electroplating process based on the current-time matching degree.

[0028] Specifically, based on the analysis results of the current-time matching degree, the central control unit further generates a current adaptability score to quantify the overall performance of the segmented electroplating process. Further, the scoring process converts the matching degree data into numerical indicators using predefined evaluation rules, comprehensively considering the current and time coordination of all segmented electroplating tanks. Understandably, this score reflects the uniformity of zinc plating layer deposition and process stability. For example, a lower score for a segmented electroplating tank with a higher matching degree indicates that the process is close to optimization, while a higher score for a tank with a lower matching degree suggests a deviation that needs adjustment. The scoring results are stored in the control unit's memory for subsequent adjustment decisions.

[0029] Step S04: When the current adaptability score is higher than the preset segmented score threshold, the current parameters of each segmented electroplating tank are adaptively adjusted according to the degree of deviation of the current adaptability score and the preset adjustment rules to generate optimized zinc plating control results.

[0030] Specifically, the central control unit compares the calculated current adaptability score with preset segmented score thresholds to determine whether current parameters need adjustment. Furthermore, when the score exceeds the threshold, it indicates significant deviations in current intensity or plating time in certain electroplating segments, potentially leading to uneven zinc plating thickness. Based on the degree of deviation, the control unit invokes preset adjustment rules to automatically calculate the current adjustment amount for each electroplating segment, such as increasing or decreasing the current intensity to balance zinc plating deposition. Understandably, the adjustment rules, based on bolt material (e.g., carbon steel or stainless steel) and electroplating tank conditions (e.g., electrolyte concentration), ensure that the adjusted current parameters optimize zinc plating quality. The adjusted parameters are sent to the current regulating devices in each electroplating segment via control commands for real-time adjustment, generating optimized zinc plating control results and recording the adjusted process parameters and expected zinc plating quality to guide subsequent production.

[0031] This embodiment provides a segmented adaptive current control method for bolt electroplating, which, compared to traditional electroplating processes, effectively solves the problems of single current control, uneven coating thickness, and insufficient process stability. By acquiring the current intensity characteristics and electroplating time characteristics of each segment of the electroplating tank in real time, the current-time matching degree is calculated and a current adaptability score is generated. Based on the score deviation, the current parameters of each segment of the electroplating tank are adaptively adjusted to ensure the uniformity and consistency of the zinc coating thickness. This significantly reduces the occurrence of localized insufficient deposition, excessive thickness, or quality defects such as scorching and pinholes, and is suitable for the industrial production needs of different bolt materials and sizes. Compared to traditional fixed current control methods, this invention optimizes the coordination of current and time during the electroplating process through dynamic monitoring and adaptive adjustment, improving the quality of the zinc coating. Simultaneously, it reduces material waste and excessive energy consumption caused by improper parameters, reduces production costs, and improves process efficiency, providing a highly efficient and reliable bolt electroplating technology for modern industry.

[0032] In some embodiments, such as Figure 2 As shown, this paper describes the steps for obtaining the process parameter sequence in a segmented current adaptive control method for bolt electroplating. Applied to an industrial bolt electroplating production line, a high-precision data acquisition system records the current intensity characteristics and segmented electroplating time characteristics of each electroplating tank in real time, providing reliable data support for subsequent adaptive current adjustment. The implementation process of this step is described in detail below, achieving efficient and accurate parameter acquisition based on the actual operating environment of the production line.

[0033] Step S21: Control the electroplating equipment to record the first characteristic timestamp when the bolt enters the first segment electroplating tank, and start monitoring the change in current intensity.

[0034] Specifically, in the actual operation of the bolt electroplating production line, the line is equipped with an automated control system that integrates high-precision timers and current sensors. When the bolt enters the first segment electroplating tank via the conveyor belt, a photoelectric sensor installed at the tank inlet detects the bolt's arrival and triggers the timer to record the current moment as the first characteristic timestamp. Furthermore, the current sensor is simultaneously activated to monitor the changes in current intensity within the electroplating tank in real time at a sampling frequency of 100 milliseconds, recording the time-series data of the current value. Understandably, the current sensor employs a high-sensitivity Hall effect sensor to ensure the capture of minute fluctuations in current, providing accurate raw data for generating current intensity characteristics.

[0035] Step S22: Control the electroplating equipment to record a second characteristic timestamp when the bolt leaves the first segmented electroplating tank, and stop monitoring the change in current intensity.

[0036] Specifically, when the bolt leaves the first segmented electroplating tank via the conveyor belt, the photoelectric sensor at the tank outlet detects the bolt's departure and triggers a timer to record the current moment as a second characteristic timestamp. Further, the control system then instructs the current sensor to stop monitoring, ending the current intensity data acquisition for that segmented electroplating tank. Understandably, after the sensor stops, the acquired current data is temporarily stored in the local storage unit of the electroplating equipment, awaiting subsequent processing to ensure data integrity and real-time performance.

[0037] Step S23: Calculate the first segmented electroplating time feature based on the first feature timestamp and the second feature timestamp.

[0038] Specifically, the central control unit obtains a first characteristic timestamp and a second characteristic timestamp from a timer, and calculates the electroplating duration of the bolt in the first segmented electroplating tank by subtracting them, forming the first segmented electroplating time characteristic. Further, this time characteristic includes the total electroplating time and the stability of the time distribution, such as checking whether the time is within a preset range (typically 30 seconds to 2 minutes, depending on the bolt size). Understandably, the calculation result is transmitted to a central database via the industrial control network, marked as the time characteristic data of the first segmented electroplating tank, for subsequent matching degree analysis.

[0039] Step S24: Generate the current intensity characteristics of the first segmented electroplating tank based on the changes in current intensity during the monitoring period.

[0040] Specifically, the central control unit processes the data collected by the current sensors in the first segment of the electroplating tank to generate current intensity characteristics. Further processing includes smoothing the current time series (e.g., using a sliding window averaging algorithm) and extracting key features such as average current intensity, maximum / minimum current values, and current fluctuation frequency. Understandably, these features reflect the stability and variation trend of the current during the electroplating process; for example, an average current intensity of 500mA with fluctuations less than ±10% is considered a stable state. The generated current intensity characteristics are stored in a central database, forming a process parameter sequence together with the time characteristics.

[0041] Step S25: Repeat the above steps to obtain the electroplating time characteristics and current intensity characteristics of other segmented electroplating tanks, forming a complete process parameter sequence.

[0042] Specifically, for other segmented electroplating tanks in the production line (e.g., the second and third segmented electroplating tanks), the above steps are repeated, recording the entry and exit timestamps of each tank sequentially, monitoring changes in current intensity, and calculating electroplating time characteristics and current intensity characteristics respectively. Furthermore, data from all segmented electroplating tanks are aggregated to the central control unit via a unified industrial control network, forming a complete sequence of process parameters containing the current intensity characteristics and segmented electroplating time characteristics of all tanks. Understandably, this sequence is stored in a database indexed by timestamps to ensure data structure, facilitating subsequent analysis and current adjustment, such as supporting real-time comparison and optimization of multiple segmented tanks.

[0043] In some embodiments, the steps of calculating the current-time matching degree and current adaptability score in the segmented current adaptive control method for a bolt electroplating zinc process are applied to an industrial bolt electroplating zinc production line. By analyzing the current intensity characteristics and segmented electroplating time characteristics of each segmented electroplating tank, a quantitative score is generated, providing a basis for subsequent adaptive current adjustment.

[0044] Specifically, the current intensity characteristics of each segment of the electroplating tank are compared with the corresponding preset optimized current standard value to obtain the current deviation coefficient.

[0045] Understandably, in the central control unit of the bolt electroplating production line, current intensity characteristic data collected from each segment of the electroplating tank is acquired. This data is recorded by high-precision current sensors and includes the average current intensity, peak value, and fluctuation range of each tank. Further, the central control unit compares the current intensity characteristics of each segment of the electroplating tank with a preset optimized current standard value. This standard value is preset based on the bolt material (such as carbon steel or stainless steel) and the target zinc coating thickness (typically 8-12 micrometers), for example, set to 500mA. The comparison process generates a current deviation coefficient by calculating the relative deviation between the actual current intensity and the standard value, indicating the degree to which the current deviates from the optimized state. Understandably, the deviation coefficient is quantified through the comparison results. For example, if the actual current of a tank is 520mA and the standard value is 500mA, the deviation coefficient reflects a positive deviation, suggesting that the current may need to be reduced to avoid excessive coating thickness.

[0046] Furthermore, the segmented electroplating time characteristics of each segmented electroplating tank are compared with the corresponding preset time standard value to obtain the time deviation coefficient.

[0047] Specifically, the central control unit extracts the segmented electroplating time characteristics of each segmented electroplating tank from the database. These characteristics are calculated based on the timestamps of the bolts entering and leaving the tank, and include the electroplating duration of each tank. Further, the control unit compares the electroplating time of each tank with a preset time standard value, which is determined according to the bolt size and electroplating process requirements; for example, a 1-minute electroplating time is suitable for bolts with a diameter of 10mm. The comparison process generates a time deviation coefficient by calculating the relative deviation between the actual electroplating time and the standard value, reflecting the degree to which the time deviates from the optimized state. Understandably, if the actual electroplating time of a tank is 65 seconds, and the standard value is 60 seconds, the deviation coefficient reflects a slightly longer time, which may affect the uniformity of the coating and requires adjustment to optimize deposition efficiency.

[0048] Furthermore, the current-time matching degree is calculated based on the current deviation coefficient and the time deviation coefficient.

[0049] Specifically, the central control unit uses an embedded algorithm to calculate the current-time matching degree based on the current deviation coefficient and time deviation coefficient of each segment of the electroplating tank. Furthermore, the algorithm comprehensively analyzes the relative magnitudes of the current and time deviations to assess their coordination during the electroplating process. For example, if the current deviation coefficient of a tank shows a high current while the time deviation coefficient shows a short electroplating time, the matching degree is low, indicating that the current and time are not optimally combined, potentially leading to uneven plating thickness. Understandably, the matching degree generates a numerical index through predefined rules, such as weighted combinations of deviation coefficients, with weights adjusted according to bolt type and electroplating tank characteristics, generating a comprehensive index reflecting process coordination, which is stored in the control unit's memory to provide a basis for subsequent scoring.

[0050] Furthermore, a current adaptability score is calculated based on the current-time matching degree, wherein the formula for calculating the current adaptability score S is: in, The actual current intensity of the i-th segmented electroplating tank. To preset and optimize the current standard value, Let i be the actual electroplating time of the i-th segmented electroplating tank. The time standard value is a preset value, and n is the total number of segmented electroplating tanks. The formula reflects the uniformity of zinc plating layer deposition in each segmented electroplating tank.

[0051] Specifically, the central control unit further calculates a current adaptability score S based on current-time matching data to quantify the performance of the entire segmented electroplating process. The scoring calculation process is as follows: First, the actual current intensity of each segmented electroplating tank is extracted from the database. (e.g., 500mA to 550mA) and actual electroplating time (For example, 60 to 70 seconds). Then, obtain the preset optimized current standard value. (e.g., 500mA) and preset time standard value (e.g., 60 seconds) These standard values ​​are pre-configured based on process specifications and bolt specifications (e.g., 10mm diameter carbon steel bolts). Next, for each segmented electroplating tank, the current deviation ratio is calculated. For example, if ( = 520mA), ( = 500mA), then the deviation ratio is At the same time, the calculation time adjustment ratio For example, if = 65 seconds), = 60 seconds, then the ratio is Multiplying the two results in the overall deviation of the groove. ,For example The overall deviation of all segmented electroplating tanks (total n, e.g., 5 tanks) is summed and averaged to obtain the current adaptability score S, for example... Understandably, this score reflects the uniformity of zinc plating deposition in each segment of the electroplating bath. A higher score indicates a greater overall deviation in current and time, requiring adjustments to optimize the plating thickness; a score close to zero indicates that the process is close to optimization. The score results are stored in the control unit database for subsequent current parameter adjustment decisions.

[0052] In some embodiments, such as Figure 3As shown, the step of adaptively adjusting the current parameters in a segmented current adaptive control method for a bolt electroplating zinc process is applied to an industrial bolt electroplating zinc production line. By dynamically adjusting the current parameters of each segmented electroplating tank based on the deviation degree of the current adaptability score, the uniformity of the zinc coating thickness and the process stability are optimized.

[0053] Step S41: Determine whether the current adaptability score is higher than the preset segmentation score threshold.

[0054] Specifically, in the central control unit of the bolt electroplating production line, a current adaptability score is obtained based on the current intensity characteristics and electroplating time characteristics of each segment of the electroplating tank. This score reflects the uniformity of the zinc coating deposition. Further, the central control unit compares this score with a preset segmental score threshold. The threshold is preset according to process specifications and bolt type (e.g., 10mm diameter carbon steel bolts), for example, set to 0.05, indicating an acceptable deviation range. The comparison process is executed by an embedded algorithm in the control unit to determine whether the score exceeds the threshold. Understandably, if the score is higher than 0.05, for example, 0.08, it indicates that the current or time deviation in some segmented electroplating tanks is large, which may lead to uneven coating thickness and requires adjustment.

[0055] Step S42: If the current is higher, then it is determined that the current parameter needs to be adjusted in the current segmented electroplating process.

[0056] Specifically, when the central control unit determines that the current adaptability score is higher than the preset segmented score threshold, it triggers an adjustment signal, indicating that there is a deviation in the current segmented electroplating process, requiring optimization of the current parameters. Further, the control unit analyzes the score value to identify the degree of deviation; for example, a score of 0.08 indicates a moderate deviation, possibly caused by excessively high current intensity or improper electroplating time in some tanks. Understandably, after determining the adjustment requirement, the control unit generates an adjustment task, marks the segmented electroplating tanks requiring optimization, and stores the task information in a database, providing a basis for subsequent calculations of the adjustment amount.

[0057] Step S43: Calculate the current adjustment amount for each segment of the electroplating tank, wherein the current adjustment amount is proportional to the current deviation coefficient of the segment of the electroplating tank.

[0058] Specifically, the central control unit calculates the corresponding current adjustment amount based on the current deviation coefficient of each segment of the electroplating tank. The current deviation coefficient is derived from the comparison between the current intensity characteristics and the preset optimized current standard value (e.g., 500mA), reflecting the degree to which the current deviates from the optimized state. Furthermore, the adjustment amount calculation employs a proportional adjustment algorithm. For example, if the current deviation coefficient of a certain tank is 0.04 (indicating that the actual current of 520mA deviates from the standard value of 500mA), the adjustment amount is determined proportionally, such as reducing it by 20mA to approach the standard value. The algorithm ensures that the adjustment amount adapts to process requirements based on the bolt material and the state of the electroplating tank (e.g., electrolyte concentration). Understandably, the adjustment amount calculation results are stored in the control unit's memory and associated with the identifiers of each segment of the electroplating tank, providing precise parameters for subsequent synchronous adjustments.

[0059] Step S44: Synchronously adjust the current parameters of each electroplating tank according to the calculated current adjustment amount.

[0060] Specifically, the central control unit sends the calculated current adjustment amount to the current regulating devices in each segment of the electroplating tank via an industrial control network (such as the Modbus protocol). Further, the current regulating devices (such as silicon controlled rectifiers) adjust the current output in real time according to the instructions, for example, reducing the current in a certain tank from 520mA to 500mA. The adjustment process ensures that all segmented electroplating tanks execute synchronously to maintain the overall coordination of the production line. Understandably, after the adjustment is completed, the control unit records the adjusted current parameters and displays the adjustment status through a human-machine interface for operator monitoring, ensuring uniform zinc plating layer deposition.

[0061] Step S45: Re-monitor the adjusted current intensity characteristics and segmented electroplating time characteristics to verify the adjustment effect.

[0062] Specifically, after the adjustment is completed, the high-precision current sensors and timers on the production line re-monitor the changes in current intensity and plating time in each segment of the electroplating tank, forming new current intensity characteristics and segmented plating time characteristics. Further, the central control unit analyzes this data, recalculates the current adaptability score, and assesses whether the adjusted process performance meets expectations, such as whether the score has dropped below a threshold (e.g., 0.05). Understandably, if the score remains high, it indicates that the adjustment effect has not met the standard, and the control unit will record the verification results and trigger further adjustments; if the score meets the requirements, the adjustment is confirmed to be effective, optimized zinc plating control results are generated, and stored in the database to guide subsequent production.

[0063] In some embodiments, the step of calculating the current adjustment amount of each segmented electroplating tank in a segmented current adaptive control method for a bolt electroplating zinc process is applied to an industrial bolt electroplating zinc production line. By identifying segmented electroplating tanks with large deviations and combining the influence of adjacent tanks, the current adjustment amount is accurately calculated, thereby optimizing the uniformity of zinc coating thickness and process stability.

[0064] Specifically, it identifies target segmented electroplating tanks where the current deviation coefficient exceeds a preset deviation threshold.

[0065] Understandably, in the central control unit of the bolt electroplating production line, the current deviation coefficient of each segment of the electroplating tank is obtained. This coefficient is generated based on the comparison between the current intensity characteristics and a preset optimized current standard value (e.g., 500mA), reflecting the degree to which the current deviates from the optimized state. Further, the central control unit compares the current deviation coefficient of each segment of the electroplating tank with a preset deviation threshold. The threshold is set according to process requirements, for example, 0.03, representing an acceptable current deviation range. The comparison process is executed through an embedded algorithm, identifying segmented electroplating tanks whose deviation coefficients exceed the threshold and marking them as target segmented electroplating tanks. For example, if the deviation coefficient of a tank is 0.04 (actual current 520mA, standard value 500mA), exceeding the threshold of 0.03, then that tank is marked as a target tank. Understandably, the marking results are stored in the control unit database for subsequent adjustment calculations.

[0066] Furthermore, for the target segmented electroplating tank, the direction of current adjustment is determined based on the sign of its current deviation coefficient.

[0067] Specifically, for the identified target segmented electroplating tank, the central control unit analyzes the sign of its current deviation coefficient to determine the direction of current adjustment. Further, if the deviation coefficient is positive, for example, 0.04 (actual current 520mA, higher than the standard value 500mA), the adjustment direction is to reduce the current; if it is negative, for example, -0.02 (actual current 490mA, lower than the standard value 500mA), the adjustment direction is to increase the current. The determination of the adjustment direction is based on process requirements, ensuring that the zinc plating layer thickness reaches the target value (e.g., 8-12 micrometers). Understandably, the adjustment direction information is associated with the identifier of the target segmented electroplating tank and stored in the control unit's memory, providing a basis for subsequent adjustment calculations.

[0068] Furthermore, the basic adjustment amount is calculated based on the absolute value of the current deviation coefficient of the target segmented electroplating tank.

[0069] Specifically, the central control unit calculates the basic adjustment amount based on the absolute value of the current deviation coefficient of the target segmented electroplating tank. Further, the calculation process employs a proportional adjustment algorithm, where the basic adjustment amount is directly proportional to the absolute value of the deviation coefficient. For example, if the absolute value of the deviation coefficient is 0.04 and the standard current is 500mA, the basic adjustment amount can be set as a direct proportion of the deviation amount, such as 20mA (0.04 × 500mA). The algorithm ensures that the adjustment amount matches the process requirements based on the bolt material (e.g., carbon steel or stainless steel) and the electroplating tank condition (e.g., electrolyte concentration). Understandably, the basic adjustment amount, as a preliminary calculation result, is stored in the control unit's memory, awaiting further correction to improve adjustment accuracy.

[0070] Furthermore, based on the influence of the current parameters of adjacent segmented electroplating tanks, the basic adjustment amount is corrected to obtain the final current adjustment amount.

[0071] Specifically, the central control unit acquires the current intensity characteristics of the preceding and following electroplating segments of the target segmented electroplating tank and analyzes their impact on the target tank. Further, the control unit calculates the current intensity difference between the target tank and adjacent tanks. If the difference is large (e.g., exceeding 50mA), it may lead to discontinuities in the zinc plating layer thickness, affecting overall uniformity. Therefore, a smoothing algorithm is used to correct the basic adjustment amount. For example, if the target tank needs a 20mA reduction, but the adjacent tank current is 510mA, the correction might be to reduce it by 15mA to balance the transition between tanks. Understandably, the corrected final current adjustment amount is sent to the current regulating device (such as a silicon controlled rectifier) ​​of the target segmented electroplating tank via the industrial control network and recorded in the database to ensure that the adjusted current parameters optimize the zinc plating layer quality.

[0072] In some embodiments, the step of correcting the current adjustment amount based on the influence of adjacent segmented electroplating tanks in a segmented current adaptive control method for a bolt electroplating process is applied to an industrial bolt electroplating production line. By analyzing the current intensity characteristics of the target segmented electroplating tank and adjacent tanks, the basic adjustment amount is smoothed and corrected to ensure the continuity and overall uniformity of the zinc coating thickness.

[0073] Specifically, the current intensity characteristics of the preceding and following electroplating segments of the target segmented electroplating tank are obtained.

[0074] Understandably, in the central control unit of the bolt electroplating production line, the current intensity characteristics of the preceding and following electroplating tanks of the target segment are extracted from the database. These characteristics are based on data collected by high-precision current sensors and include average current intensity, peak value, and fluctuation range. Further, the target segment electroplating tank is the tank previously identified whose current deviation coefficient exceeds a preset deviation threshold, such as the second segment electroplating tank, whose preceding tank is the first segment electroplating tank, and whose following tank is the third segment electroplating tank. The control unit obtains the current intensity characteristics of these adjacent tanks through an industrial control network (such as the Modbus protocol), for example, the average current of the first tank is 510mA, and that of the third tank is 505mA. Understandably, these characteristic data are stored in the database and associated with the target tank's identifier, providing a basis for subsequent difference analysis.

[0075] Further, the current intensity difference between the target segmented electroplating tank and the adjacent segmented electroplating tank is calculated.

[0076] Specifically, the central control unit uses an embedded algorithm to calculate the difference between the current intensity characteristics of the target segmented electroplating tank and the preceding and following segmented electroplating tanks. Further, the algorithm uses the average current intensity of the target tank as a benchmark; for example, if the second tank is 520mA, the difference between it and the first tank (510mA) is 10mA, and the difference between it and the third tank (505mA) is 15mA. The difference calculation is based on the stability of the current characteristics, for example, using only the smoothed average current value to reduce fluctuation interference. Understandably, the calculation results are stored in the control unit's memory, labeled as the current intensity difference between the target tank and adjacent tanks, for evaluating inter-tank current coordination.

[0077] Furthermore, when the current intensity difference exceeds a preset continuity threshold, the basic adjustment amount is smoothed and corrected.

[0078] Specifically, the central control unit compares the calculated current intensity difference with a preset continuity threshold, which is set according to process requirements, such as 50mA, to ensure a smooth transition in the zinc plating thickness between adjacent tanks. Further, if the difference between the target tank and an adjacent tank exceeds the threshold, for example, the difference between the second and third tanks is 60mA (520mA - 460mA), a smoothing correction is triggered. The correction process uses a linear interpolation algorithm to proportionally adjust the base adjustment amount (e.g., a reduction of 20mA), for example, by reducing it by 15mA, to reduce the current difference with adjacent tanks. Understandably, the smoothing correction, based on the bolt material (e.g., carbon steel) and the electroplating tank condition (e.g., electrolyte concentration), ensures continuous plating thickness after adjustment, reducing abrupt thickness changes in the transition area between tanks.

[0079] Furthermore, the corrected current adjustment amount is used as the final current adjustment amount for the target segmented electroplating tank.

[0080] Specifically, the central control unit determines the smoothed and corrected current adjustment amount as the final current adjustment amount for the target segmented electroplating tank; for example, the final adjustment amount for the second tank is a reduction of 15mA. Further, this adjustment amount is sent via the industrial control network to the current regulating device (such as a silicon controlled rectifier) ​​of the target segmented electroplating tank, adjusting the current output in real time, for example, reducing it from 520mA to 505mA. After adjustment, the control unit records the final current adjustment amount and the corresponding tank identifier, stores it in the database, and displays the adjustment status through a human-machine interface. Understandably, the final adjustment amount ensures that the current of the target tank is consistent with that of adjacent tanks, optimizing the overall uniformity of the zinc plating layer and the stability of the process.

[0081] Understandably, the process parameter sequence acquisition and processing steps in a segmented current adaptive control method for a bolt electroplating zinc process are applied to an industrial bolt electroplating zinc production line. By adopting a standardized data transmission protocol and data processing algorithm, the accurate acquisition and smoothing of the current intensity characteristics and segmented electroplating time characteristics of each segmented electroplating tank are ensured, providing a reliable data foundation for subsequent adaptive control.

[0082] Specifically, in the actual operation of the bolt electroplating production line, the electroplating equipment is equipped with high-precision current sensors and timers to collect process parameter sequences, including the current intensity characteristics and electroplating time characteristics of each segment of the electroplating tank. Data acquisition is achieved through standardized industrial communication protocols, with the Modbus protocol being preferred due to its wide compatibility and low latency in industrial automation. For example, the current sensors and timers of each segment of the electroplating tank communicate with the central control unit via Modbus RTU mode, transmitting current intensity and time data at a frequency of 10 times per second. Furthermore, if the production line requires higher integration and data security, it can switch to the OPC UA protocol, ensuring reliable data transmission in complex network environments through its TCP / IP-based communication framework. Understandably, the collected process parameter sequences are stored in the central control unit's database, labeled as raw data for each segment of the electroplating tank, providing a basis for subsequent processing.

[0083] Furthermore, to address the fluctuations in current intensity, the central control unit employs a sliding window averaging algorithm to smooth the collected current intensity data, generating stable current intensity characteristics. The sliding window averaging algorithm calculates the average value of the current data within a fixed time window (e.g., 500 milliseconds). For example, if the current data sequence for a segmented electroplating tank is [510mA, 515mA, 520mA, 518mA, 512mA], the algorithm calculates the average value of the first window (510+515+520) / 3=515mA with a window size of 3, and then continues to slide to generate the smoothed current sequence. Understandably, the smoothing process effectively filters out noise in the current fluctuations (such as power supply fluctuations or sensor interference), ensuring that the current intensity characteristics accurately reflect the true state of the electroplating process. The processed data is stored in a database, forming a complete process parameter sequence together with the segmented electroplating time characteristics for subsequent analysis and adjustment.

[0084] In some embodiments, the step of generating and executing optimized zinc plating control results in a segmented current adaptive control method for a bolt electroplating zinc process is applied to an industrial bolt electroplating zinc production line. By sending the optimized current parameters to the control platform and generating control commands, precise current adjustment of each segmented electroplating tank is achieved, ensuring uniformity of zinc plating layer thickness and process stability.

[0085] Specifically, the optimized galvanizing control results are sent to the control platform of the bolt electro-galvanizing production line.

[0086] Understandably, in the central control unit of the bolt electroplating production line, after generating optimized galvanizing control results, the results data is transmitted to the control platform via an industrial control network. The optimized galvanizing control results include the adjusted current parameters for each segment of the electroplating tank; for example, the current in the second segment electroplating tank is adjusted from 520mA to 505mA. Furthermore, the data transmission uses the Modbus protocol to ensure high reliability and low latency, for example, sending the adjustment parameters to the control platform at a frequency of 5 times per second. The control platform, an industrial computer or PLC (Programmable Logic Controller), is responsible for coordinating the production line operation. Understandably, the transmitted data includes the identifier of each segment of the electroplating tank and the corresponding current adjustment amount, stored in the control platform's database, providing a basis for subsequent instruction generation.

[0087] Furthermore, the control platform generates segmented current control commands based on the optimized galvanizing control results.

[0088] Specifically, after receiving the optimized galvanizing control results, the control platform generates segmented current control commands using its built-in control algorithm. Further, the algorithm generates specific current adjustment commands based on the adjustment parameters of each segment of the electroplating tank; for example, it instructs the current regulating device of the second segment of the electroplating tank to set the current to 505mA. The command format follows industry standard protocols to ensure compatibility with the current regulating device. Understandably, when generating commands, the control platform ensures that the commands can optimize the uniformity of the galvanized layer thickness based on the bolt material (e.g., carbon steel) and the electroplating tank condition (e.g., electrolyte concentration). After the commands are generated, they are temporarily stored in the control platform's memory, awaiting transmission.

[0089] Furthermore, the segmented current control command is sent to the current regulating device of the corresponding segmented electroplating tank.

[0090] Specifically, the control platform sends segmented current control commands to the current regulating devices of each segmented electroplating tank via an industrial control network (such as the Modbus protocol). Further, the current regulating device is a silicon controlled rectifier (SCR) that adjusts the current output in real time after receiving the command, for example, adjusting the current of the second segmented electroplating tank from 520mA to 505mA. The transmission process uses a point-to-point communication mode to ensure the accuracy of the commands for each segmented electroplating tank. Understandably, after the command is sent, the control platform records the transmission status and displays the command execution progress through a human-machine interface for operator monitoring, ensuring the adjustment process is efficient and reliable.

[0091] Furthermore, the current changes in each segmented electroplating tank after executing the segmented current control command are monitored.

[0092] Specifically, after executing the control command, high-precision current sensors in each electroplating tank monitor the changes in current intensity in real time after adjustment. For example, they check whether the actual current in the second electroplating tank is stable within the range of 505mA ± 5mA. Furthermore, the monitoring data is transmitted back to the control platform via the industrial control network, generating new current intensity characteristics and storing them in the database. The control platform analyzes this data to evaluate the adjustment effect, such as checking whether the current is close to the preset optimized current standard value (e.g., 500mA) to verify the uniformity of the zinc plating layer deposition. Understandably, if monitoring reveals that the current in a certain tank still deviates, the control platform will record the anomaly and trigger further analysis. Based on the previously calculated current adaptability score (reflecting the uniformity of the zinc plating layer), it will determine whether further adjustments are needed to ensure process stability.

[0093] In some embodiments, the step of verifying the effect of current parameter adjustment in a segmented current adaptive control method for a bolt electroplating zinc process is applied to an industrial bolt electroplating zinc production line. By re-monitoring the adjusted current intensity characteristics and segmented electroplating time characteristics and recalculating the current adaptability score, the uniformity of zinc coating thickness and process stability are ensured.

[0094] Specifically, after the current parameters are adjusted, the changes in current intensity and corresponding electroplating time in each electroplating tank segment are monitored.

[0095] Understandably, after the current parameters of the bolt electroplating production line are adjusted, for example, by adjusting the current of the second segment electroplating tank from 520mA to 505mA, high-precision current sensors and timers in each segment electroplating tank continue to monitor changes in current intensity and electroplating time at a sampling frequency of 100 milliseconds. Furthermore, the current sensors record the adjusted current data for each tank, such as the average current intensity and fluctuation range, and the timers record the time it takes for the bolt to enter and leave each tank, forming new time data. Understandably, this monitoring data is transmitted in real-time to the central control unit via an industrial control network (such as the Modbus protocol), stored in a database, and tagged with adjusted current intensity characteristics and segment electroplating time characteristics, providing a basis for subsequent analysis.

[0096] Furthermore, the current adaptability score is recalculated based on the adjusted monitoring data.

[0097] Specifically, the central control unit recalculates the current adaptability score based on the adjusted current intensity characteristics and segmented electroplating time characteristics to evaluate the adjustment effect. Furthermore, the scoring process is completed through an embedded algorithm, comprehensively analyzing the deviations of the current intensity and electroplating time of each segmented electroplating tank from the preset optimized standard values ​​to generate a new score reflecting the uniformity of zinc layer deposition. For example, if the average current of the second tank after adjustment is 505mA and the electroplating time is 60 seconds, close to the preset standard value (500mA, 60 seconds), the score is lower than before the adjustment, indicating that the process is more optimized. Understandably, the recalculated score is stored in the control unit database and correlated with the score before adjustment for easy comparison and verification.

[0098] Furthermore, the recalculated current adaptability score is compared with the preset segmentation score threshold.

[0099] Specifically, the central control unit compares the recalculated current adaptability score with a preset segmented scoring threshold (e.g., 0.05), which is set based on the bolt type (e.g., 10mm diameter carbon steel bolts) and process specifications. Further, the comparison process is executed by the control unit's algorithm to determine if the score is below the threshold. A score below the threshold indicates that the adjusted current parameters have optimized the uniformity of the galvanized layer. For example, if the recalculated score is 0.03, which is below the threshold of 0.05, it indicates that the adjustment is effective. Understandably, the comparison results are displayed through a human-machine interface for operator monitoring and stored in a database for subsequent decision-making.

[0100] Furthermore, if the recalculated current adaptability score is still higher than the preset segmented score threshold, the current parameter adjustment step is repeated until the control requirements are met.

[0101] Specifically, if the recalculated current adaptability score is still higher than the preset segmental score threshold (e.g., a score of 0.07, higher than 0.05), it indicates that the adjusted current parameters have not yet reached an optimized state, and the central control unit triggers a repetitive adjustment process. Further, based on the new monitoring data, the control unit recalculates the current adjustment amount for each segment of the electroplating tank, for example, further adjusting the current of the second tank to 500mA, and sends this to the current regulating device (such as a thyristor rectifier) ​​via the industrial control network for execution. Monitoring and scoring are repeated after adjustment until the score is lower than the threshold, meeting the control requirements. Understandably, data from each iteration of the repetitive adjustment process is recorded in the database to ensure continuous process optimization, ultimately achieving uniform zinc plating thickness and process stability.

[0102] In some embodiments, the segmented electroplating process monitoring step in a segmented current adaptive control method for a bolt electroplating zinc process is applied to an industrial bolt electroplating zinc production line. By recording current adjustment data in real time, establishing a historical database, and optimizing preset standard values, the long-term stability of the process and the quality of the zinc plating layer are improved.

[0103] Specifically, during each current parameter adjustment process, the current values ​​before adjustment, the adjustment amount, and the value after adjustment for each segment of the electroplating tank are recorded in real time.

[0104] Understandably, during each current parameter adjustment process in the bolt electroplating production line, for example, adjusting the current of the second-section electroplating tank from 520mA to 505mA, the central control unit records relevant data in real time via an industrial control network (such as the Modbus protocol). Furthermore, the recorded content includes the current intensity value before adjustment (e.g., 520mA), the calculated adjustment amount (e.g., a reduction of 15mA), and the current intensity value after adjustment (e.g., 505mA). This data is provided by high-precision current sensors and associated with the identification and timestamp of the corresponding electroplating tank section. Understandably, the recorded data is stored in the temporary memory of the central control unit, and the adjustment process is displayed through a human-machine interface for real-time monitoring by the operator, ensuring data accuracy and traceability.

[0105] Furthermore, a historical database of current parameter adjustments for segmented electroplating tanks is established to store historical adjustment records and corresponding zinc plating quality results.

[0106] Specifically, the central control unit aggregates the recorded data from each current parameter adjustment to construct a historical database of current parameter adjustments for the segmented electroplating tanks. Furthermore, the database employs a structured storage method, such as using an SQL database, storing fields for each record including the segmented electroplating tank number, adjustment time, current before adjustment, adjustment amount, current after adjustment, and the corresponding zinc plating quality result (e.g., zinc plating thickness detected by a thickness gauge, such as 8-12 micrometers). Understandably, the zinc plating quality result is obtained through quality inspection equipment at the end of the production line, such as an X-ray fluorescence thickness gauge, recording the plating thickness and uniformity, and storing it in association with the adjustment records to provide data support for subsequent optimization.

[0107] Furthermore, based on the adjustment records in the historical database, the preset optimized current standard value and preset time standard value in the subsequent electroplating process are optimized.

[0108] Specifically, the central control unit utilizes historical database adjustment records and galvanizing quality results to employ data analysis algorithms to optimize the preset current and time standard values ​​for subsequent electroplating processes. Furthermore, the analysis algorithm identifies the optimal current and time combinations associated with high-quality galvanized layers (e.g., uniform thickness, 8-12 micrometers) by statistically analyzing historical data. For example, it finds that the combination of 500mA and 60 seconds works best on carbon steel bolts, and then updates the standard values ​​(e.g., adjusting from 510mA to 500mA). The algorithm ensures that the optimization results are applicable to different production scenarios based on bolt material and batch variations. Understandably, the optimized standard values ​​are stored in the database and updated to the production line configuration file via the control platform, providing a more accurate reference for subsequent electroplating.

[0109] Furthermore, the calculation benchmark for the current adaptability score is updated based on the optimized preset standard value.

[0110] Specifically, the central control unit updates the calculation benchmark for the current adaptability score based on optimized preset current standard values ​​(e.g., 500mA) and preset time standard values ​​(e.g., 60 seconds). This score is used to evaluate the uniformity of zinc plating deposition. Further, the update process involves modifying the standard value parameters in the embedded algorithm; for example, adjusting the original benchmarks of 510mA and 62 seconds to 500mA and 60 seconds to ensure the score calculation reflects the latest process optimization goals. The score is based on the deviation of the adjusted current intensity and plating time from the new standard values, generating a more accurate evaluation result. Understandably, the updated calculation benchmark is applied to subsequent plating batches, the update status is displayed through a human-machine interface, and the data is stored in a database to ensure continuous process improvement and stable zinc plating quality.

[0111] The present invention also provides a segmented current adaptive control system 100 for the bolt electroplating zinc process, such as... Figure 4As shown, this system, applied to an industrial bolt electroplating production line, achieves adaptive control of current parameters through data acquisition, processing, and current adjustment modules, thereby optimizing the quality of the zinc plating layer. The segmented current adaptive control system 100 for the bolt electroplating process includes: The data acquisition module 101 is configured to acquire the process parameter sequence in the bolt electroplating zinc process, wherein the process parameter sequence includes at least a set of current intensity characteristics and segmented electroplating time characteristics of the bolt in the segmented electroplating tank.

[0112] Specifically, the data acquisition module 101 consists of current sensors and timers installed in each segmented electroplating tank, used to acquire the process parameter sequence of the bolt electroplating zinc process. Further, the current sensors monitor the current intensity of each tank in real time, generating current intensity characteristics such as average current value and fluctuation trend. The timers record the time when the bolt enters and leaves the tank, forming segmented electroplating time characteristics, such as the electroplating duration. Understandably, the acquired data is transmitted to the central control unit via an industrial control network and stored in a database, providing reliable data for subsequent processing.

[0113] The data processing module 102 is configured to calculate the current-time matching degree based on the current intensity characteristics and the segmented electroplating time characteristics, and to determine the current adaptability score of the segmented electroplating process based on the current-time matching degree.

[0114] Specifically, the data processing module 102 runs within the embedded system of the central control unit, processing the collected current intensity characteristics and segmented electroplating time characteristics. Further, the module compares these characteristics with preset standard values, calculates the current-time matching degree, and evaluates the coordination between current and time during the electroplating process. If the matching degree is low, indicating a deviation, the module generates a higher current adaptability score, reflecting uneven plating thickness. Understandably, the score results are stored in memory for use in current adjustment.

[0115] The current adjustment module 103 is configured to, when the current adaptability score is higher than the preset segment score threshold, adaptively adjust the current parameters of each segment electroplating tank according to the degree of deviation of the current adaptability score and a preset adjustment rule, so as to generate an optimized zinc plating control result.

[0116] Specifically, the current adjustment module 103 operates within the central control unit, comparing the current adaptability score with preset segmented score thresholds. Further, if the score exceeds the threshold, indicating a deviation, the module calculates the adjustment amount using an adjustment algorithm based on the degree of deviation, and adjusts the current parameters of each tank to near the standard value via the current adjustment device. Understandably, the adjusted parameters, as the optimized galvanizing control result, are stored in a database and displayed through a human-machine interface to ensure the uniformity of the galvanized layer.

[0117] The above description is merely an exemplary embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the technical concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A segmented current adaptive control method for bolt electroplating zinc process, characterized in that, Applied to bolt electroplating production lines, it optimizes the quality of the zinc plating layer through segmented current adaptive control, including: Obtain the process parameter sequence in the bolt electroplating zinc process, wherein the process parameter sequence includes at least a set of current intensity characteristics and segmented electroplating time characteristics of the bolt in the segmented electroplating tank; Calculate the current-time matching degree based on the current intensity characteristics and the segmented electroplating time characteristics; The current adaptability score of the segmented electroplating process is determined based on the current-time matching degree. When the current adaptability score is higher than the preset segmented score threshold, the current parameters of each segmented electroplating tank are adaptively adjusted according to the degree of deviation of the current adaptability score and the preset adjustment rules to generate optimized zinc plating control results.

2. The segmented current adaptive control method for the bolt electroplating zinc process according to claim 1, characterized in that, The steps for obtaining the process parameter sequence in the bolt electroplating zinc process include: The electroplating equipment records a first characteristic timestamp when the bolt enters the first segment electroplating tank and begins monitoring changes in current intensity. The electroplating equipment is controlled to record a second characteristic timestamp when the bolt leaves the first segmented electroplating tank, and to stop monitoring changes in current intensity. Calculate the first segmented electroplating time feature based on the first feature timestamp and the second feature timestamp; The current intensity characteristics of the first segmented electroplating tank are generated based on the changes in current intensity during the monitoring period. Repeat the above steps to obtain the electroplating time and current intensity characteristics of other segmented electroplating tanks.

3. The segmented current adaptive control method for the bolt electroplating zinc process according to claim 2, characterized in that, The step of calculating the current-time matching degree based on the current intensity characteristics and the segmented electroplating time characteristics, and determining the current adaptability score of the segmented electroplating process based on the current-time matching degree, includes: The current intensity characteristics of each segment of the electroplating tank are compared with the corresponding preset optimized current standard value to obtain the current deviation coefficient. The segmented electroplating time characteristics of each segmented electroplating tank are compared with the corresponding preset time standard value to obtain the time deviation coefficient; Calculate the current-time matching degree based on the current deviation coefficient and the time deviation coefficient; The current adaptability score is calculated based on the current-time matching degree, wherein the formula for calculating the current adaptability score S is: in, The actual current intensity of the i-th segmented electroplating tank. To preset and optimize the current standard value, Let i be the actual electroplating time of the i-th segmented electroplating tank. The time standard value is a preset value, and n is the total number of segmented electroplating tanks. The formula reflects the uniformity of zinc plating layer deposition in each segmented electroplating tank.

4. The segmented current adaptive control method for the bolt electroplating zinc process according to claim 3, characterized in that, The preset segmented control condition is that the current adaptability score is higher than the preset segmented score threshold. The step of adaptively adjusting the current parameters of each segmented electroplating tank according to the deviation of the current adaptability score and a preset adjustment rule includes: Determine whether the current adaptability score is higher than the preset segmentation score threshold; If the value is higher, then the current parameter needs to be adjusted in the current segmented electroplating process; Calculate the current adjustment amount for each segment of the electroplating tank, wherein the current adjustment amount is proportional to the current deviation coefficient of the segment of the electroplating tank. The current parameters of each segmented electroplating tank are adjusted synchronously according to the calculated current adjustment amount.

5. The segmented current adaptive control method for the bolt electroplating zinc process according to claim 4, characterized in that, The step of calculating the current adjustment amount for each segment of the electroplating tank further includes: Identify target segmented electroplating tanks where the current deviation coefficient exceeds a preset deviation threshold; For the target segmented electroplating tank, the direction of current adjustment is determined according to the sign of its current deviation coefficient; The basic adjustment amount is calculated based on the absolute value of the current deviation coefficient of the target segmented electroplating tank; The basic adjustment amount is corrected based on the influence of the current parameters of adjacent electroplating tanks to obtain the final current adjustment amount.

6. The segmented current adaptive control method for the bolt electroplating zinc process according to claim 5, characterized in that, The step of correcting the basic adjustment amount based on the influence of current parameters of adjacent segmented electroplating tanks includes: Obtain the current intensity characteristics of the preceding and following segments of the target segmented electroplating tank; Calculate the current intensity difference between the target segmented electroplating tank and the adjacent segmented electroplating tank; When the current intensity difference exceeds a preset continuity threshold, the basic adjustment amount is smoothed and corrected. The corrected current adjustment amount is used as the final current adjustment amount for the target segmented electroplating tank.

7. The segmented current adaptive control method for bolt electroplating zinc process according to any one of claims 1 to 6, characterized in that, After generating the optimized galvanizing control results, the process also includes: The optimized galvanizing control results are sent to the control platform of the bolt electrogalvanizing production line. The control platform generates segmented current control commands based on the optimized galvanizing control results. The segmented current control command is sent to the current regulating device of the corresponding segmented electroplating tank; Monitor the current changes in each segment of the electroplating tank after executing the segmented current control command.

8. The segmented current adaptive control method for the bolt electroplating zinc process according to claim 4, characterized in that, The step of re-monitoring the adjusted current intensity characteristics and segmented electroplating time characteristics to verify the adjustment effect further includes: After the current parameters are adjusted, continue to monitor the changes in current intensity and corresponding electroplating time in each electroplating tank segment; The current adaptability score was recalculated based on the adjusted monitoring data; The recalculated current adaptability score is compared with the preset segmentation score threshold; If the recalculated current adaptability score is still higher than the preset segmented score threshold, the current parameter adjustment step is repeated until the control requirements are met.

9. The segmented current adaptive control method for the bolt electroplating zinc process according to claim 8, characterized in that, Further steps include monitoring the segmented electroplating process: During each current parameter adjustment process, the current value before adjustment, the adjustment amount, and the value after adjustment of each segment of the electroplating tank are recorded in real time. Establish a historical database of current parameter adjustments for segmented electroplating tanks, storing historical adjustment records and corresponding zinc plating quality results; Based on the adjustment records in the historical database, the preset optimized current standard value and preset time standard value are optimized in the subsequent electroplating process; The calculation benchmark for the current adaptability score is updated based on the optimized preset standard value.

10. A segmented current adaptive control system for a bolt electroplating zinc process, characterized in that, Applications in bolt electroplating production lines include: The data acquisition module is configured to acquire the process parameter sequence in the bolt electroplating zinc process, wherein the process parameter sequence includes at least a set of current intensity characteristics and segmented electroplating time characteristics of the bolt in the segmented electroplating tank; The data processing module is configured to calculate the current-time matching degree based on the current intensity characteristics and the segmented electroplating time characteristics, and to determine the current adaptability score of the segmented electroplating process based on the current-time matching degree. The current adjustment module is configured to adaptively adjust the current parameters of each segment of the electroplating tank according to a preset adjustment rule based on the degree of deviation of the current adaptability score when the current adaptability score is higher than the preset segment score threshold, thereby generating optimized zinc plating control results.

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