Intelligent detection and self-adaptive control device of brush plating machine

Abstract

The invention relates to the technical field of automatic brush plating, in particular to an intelligent detection and self-adaptive control device of a brush plating machine, which comprises a workpiece size detection module, a liquid concentration detection module, a forward and backward mechanism, a lifting mechanism, a rotating mechanism and a brush plating functional unit. By integrating an intelligent detection sensor and a real-time control system, precise detection of the size of a workpiece and dynamic regulation and control of the thickness of a plating layer are realized, and the flow velocity of an electroclean liquid is optimized by utilizing a PID calculus algorithm to ensure that the ion flow velocity is in an optimal state. The brush plating efficiency and quality can be remarkably improved, the controllability and traceability of the process are enhanced, and the requirements of modern industry for efficient and accurate brush plating are met.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of automatic brush plating, and particularly relates to an intelligent detection and self-adaptive control device of a brush plating machine. BACKGROUND

[0002] As an important surface treatment process, brush plating technology is widely used in mechanical manufacturing, aerospace, automobile industry and other fields. It deposits a metal layer on the surface of a workpiece through an electrochemical method to improve the wear resistance, corrosion resistance or repair the damaged surface of the workpiece. However, the traditional brush plating equipment has many deficiencies in practical application, especially in intelligent detection and self-adaptive control. The existing brush plating equipment usually relies on manual operation to complete key steps such as workpiece loading, size detection, plating layer thickness control and the like. This way not only is low in efficiency, but also is prone to unstable plating layer quality due to human factors. In addition, the traditional equipment lacks real-time monitoring and dynamic adjustment capability for liquid component concentration, ion flow rate and plating layer thickness in the brush plating process, and is difficult to meet the high-precision and high-quality brush plating demand.

[0003] On the other hand, although the existing automatic brush plating system reduces manual intervention to some extent, there is still much room for improvement in terms of intelligence and self-adaptive capability. For example, the existing system often cannot automatically calculate the required total amount of ions according to the actual size of the workpiece and the preset plating layer thickness, and it is also difficult to dynamically adjust the brush plating parameters through real-time monitoring of current value, liquid concentration and flow, thereby affecting the uniformity and consistency of the plating layer. In addition, the traditional brush plating equipment lacks efficient cooperative control capability in the multi-step brush plating process, and the cooperation between functional units is not close enough, which may lead to poor connection between processes, thereby affecting the overall production efficiency and product quality.

[0004] In view of the above problems, it is particularly important to develop a brush plating machine with intelligent detection and self-adaptive control function. The device should be able to realize automatic detection of workpiece size, accurate calculation of plating layer thickness and real-time monitoring and dynamic adjustment of various parameters in the brush plating process, thereby significantly improving the brush plating quality and production efficiency. At the same time, by introducing advanced sensor technology, PID control algorithm and image monitoring system, the stability and reliability of the brush plating process can be further optimized, providing an efficient and intelligent solution for the surface treatment field. SUMMARY

[0005] The present application proposes an intelligent detection and self-adaptive control device of a brush plating machine to solve the problems of insufficient workpiece size detection, plating layer thickness control and brush plating process automation of existing brush plating machines. The device realizes accurate detection of workpiece size and dynamic regulation of plating layer thickness by integrating intelligent detection sensors, real-time control systems and multi-module cooperative driving mechanisms.

[0006] The application provides an intelligent detection and self-adaptive control device of a brush plating machine, which comprises a workpiece size detection module, a liquid concentration detection module, a forward and backward mechanism, a lifting mechanism, a rotating mechanism and a brush plating function unit. The workpiece size detection module is composed of an intelligent detection sensor and a single-chip microcomputer. The intelligent detection sensor is used for collecting the geometric parameters of the workpiece to be plated and transmitting the data to the single-chip microcomputer. The single-chip microcomputer calculates the total amount of various ions required in the brush plating process based on a preset plating layer thickness algorithm and stores the data in a database.

[0007] Further, the liquid concentration detection module is arranged in five liquid storage pools, each of which is equipped with a concentration sensor for real-time monitoring of the effective component concentration in the liquid. The system algorithm dynamically adjusts the plating layer thickness in the brush plating process according to the data fed back by the concentration sensor in combination with the liquid flow information to ensure that the plating layer thickness reaches the set value to automatically terminate the current step and enter the next process.

[0008] In particular, the forward and backward mechanism is composed of a stepping motor, a screw block assembly and a PLC control system. The PLC control system receives the signal of the position sensor to determine whether the workpiece reaches the specified chuck position. When the workpiece is in place, the PLC drives the chuck to clamp the workpiece through the pneumatic system. Further, the lifting mechanism is composed of a stepping motor, a speed reducer, a straight angle turning mechanism composed of multiple screw nut assemblies and a PLC control system. The PLC control system drives the lifting mechanism to lift the brush plating function unit to a predetermined height to complete the preparation work before brush plating.

[0009] Further, the brush plating function unit comprises a plurality of brush plating heads, each of which corresponds to a different brush plating step.

[0010] S1: The PLC program drives the forward and backward mechanism to drive the first brush plating head to extend into the workpiece, and simultaneously starts the electric cleaning liquid pump to make the electric cleaning liquid circulate. While the electric cleaning liquid flows to the surface of the workpiece, the brush plating function circuit is started, the current reversing system sets the current direction to be positive, and the voltage is fixed at 10V. The current passing through the ions to be removed on the surface of the workpiece flows to the electric cleaning liquid tank along the electric cleaning liquid, and the impurities and ions are precipitated and periodically removed. The system monitors the current value in real time, and the current value represents the ion movement speed. Based on the previous experimental data, the system calculates the required ion flow through the PID integral algorithm and outputs an analog signal to the electric cleaning liquid pump to adjust the electric cleaning liquid flow rate, so that the ion flow rate is in the best state. The system dynamically calculates the total amount of ions in combination with the running time and assists in judging whether this step is completed through the image monitoring system.

[0011] S2: The PLC program drives the forward and backward mechanism to exit the first brush plating head from the workpiece, and drives the rotating mechanism to rotate by a preset angle, so that the second brush plating head is in place, preparing for the next activation liquid working stage. Further, the rotating mechanism is composed of a stepping motor, a transmission gear set and an angle sensor. The angle sensor is used to detect the rotation angle and feed back the data to the PLC control system, and the PLC accurately controls the rotation action according to the preset angle, ensuring the accuracy of the brush plating head switching process. In addition, the brush plating function circuit also includes a current reversing system, which can dynamically adjust the current direction and size according to the brush plating step requirements, so as to adapt to the requirements of different brush plating processes.

[0012] The beneficial effects of the present application are:

[0013] By integrating intelligent detection sensors and real-time control systems, the accuracy of workpiece size detection and the uniformity of plating layer thickness during the brush plating process are significantly improved; by optimizing the design of the brush plating function unit and the cooperation of the multi-module cooperative driving mechanism, the brush plating process is highly automated; in particular, the PID integral algorithm dynamically regulates the flow rate of the electric cleaning liquid, so that the ion flow rate is always kept at the best state, thereby improving the efficiency and quality of brush plating. In addition, the system algorithm combines real-time monitoring and database storage technology, further enhancing the controllability and traceability of the brush plating process, meeting the needs of modern industrial production for efficient and accurate brush plating BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 The present application is a schematic diagram of the overall structure, which shows the main components of the intelligent detection and adaptive control device of the brush plating machine and their mutual relationship;

[0015] Figure 2 The workpiece size detection module and the liquid concentration detection module of the present application are shown in the schematic diagram, which details the arrangement and connection method of the intelligent detection sensor, the single-chip microcomputer and the concentration sensor;

[0016] Figure 3 The cooperative working schematic diagram of the forward and backward mechanism, the lifting mechanism and the rotating mechanism of the present application is shown, which shows the specific structure and operation logic of the stepping motor, the screw block assembly, the speed reducer, the multiple screw nuts and the transmission gear set;

[0017] Figure 4 The brush plating function unit and the electric cleaning liquid circulation system of the present application are shown in the schematic diagram, which shows the layout and function implementation process of the brush plating head, the electric cleaning liquid pump, the current reversing system and the image monitoring system.

[0018] The reference signs are as follows:

[0019] 1. Intelligent detection sensor; 2. Microcontroller; 3. Concentration sensor; 4. Liquid storage tank; 5. Stepper motor; 6. Lead screw and slider assembly; 7. Reducer; 8. Multiple sets of lead screw nuts; 9. Transmission gear set; 10. Angle sensor; 11. Brush plating head; 12. Electroplating solution pump; 13. Current reversing system; 14. Image monitoring system; 15. PLC control system; 16. Pneumatic system; 17. Chuck; 18. Workpiece to be plated; 19. Electroplating solution tank; 20. PID calculation module; 21. Brush plating solution supply flow rate module; 22. Current module; 23. Voltage setting module; 24. Plating thickness detection module; 25. Database. Detailed Implementation

[0020] This invention relates to an intelligent detection and adaptive control device for a brush plating machine. By integrating intelligent detection sensors, a real-time control system, and a multi-module collaborative drive mechanism, it achieves precise detection of workpiece dimensions and dynamic control of plating thickness. (See attached diagram.) Figure 1 To be continued Figure 4 The specific embodiments of the present invention will be described in detail below.

[0021] In this embodiment, as Figure 1 As shown, the intelligent detection and adaptive control device of the entire brush plating machine includes a workpiece size detection module, a liquid concentration detection module, a forward / backward mechanism, a lifting mechanism, a rotation mechanism, and a brush plating functional unit. The modules coordinate with each other through a PLC control system 15 to ensure a high degree of automation and accuracy in the brush plating process. The copper workpiece 18 to be plated is conveyed to the designated position via a feeding device, at which point the intelligent detection sensor 1 begins operation. The intelligent detection sensor 1 collects the geometric parameters of the workpiece using non-contact measurement technology and transmits the data to the microcontroller 2. The microcontroller 2 calculates the total amount of various ions required during the brush plating process based on a preset plating thickness algorithm and stores this data in the database 25. This process provides a reliable basis for subsequent brush plating steps.

[0022] The core component of the liquid concentration detection module is the concentration sensor 3, which is installed in five liquid storage tanks 4. Each liquid storage tank 4 is equipped with a concentration sensor 3 for real-time monitoring of the concentration of the active ingredient in the liquid. Figure 2 As shown, the concentration sensor 3 is connected to the PLC control system 15 via a signal line, providing real-time feedback of liquid concentration information. The system algorithm dynamically adjusts the coating thickness during the brush plating process based on the data from the concentration sensor 3 and the liquid flow rate information. For example, when the concentration of an effective component in a liquid is lower than a set value, the system automatically adjusts the liquid supply flow rate to ensure the coating thickness reaches the set value. The coating thickness detection module 24 further improves the controllability of coating quality by monitoring changes in coating thickness in real time.

[0023] The forward and backward mechanism consists of a stepper motor 5, a lead screw and slider assembly 6, and a PLC control system 15, such as... Figure 3 As shown. When the workpiece reaches the designated position, the position sensor detects the workpiece position and transmits the signal to the PLC control system 15. The PLC control system 15 drives the chuck 17 to clamp the workpiece via the pneumatic system 16, ensuring the workpiece remains stable during the brush plating process. Subsequently, the PLC program drives the forward and backward mechanism via the stepper system to move the brush plating functional unit to the predetermined position. The forward movement is achieved by the stepper motor 5 driving the lead screw slider assembly 6, ensuring that the brush plating head 11 can accurately reach the inside of the workpiece.

[0024] The design of the lifting mechanism further enhances the flexibility of the brush plating functional unit. The lifting mechanism consists of a right-angle steering mechanism composed of a stepper motor 5, a reducer 7, and multiple sets of lead screws and nuts 8, as well as a PLC control system 15. (For example...) Figure 3 As shown, the PLC control system 15 drives the stepper motor 5 to raise the lifting mechanism to a predetermined height. The lifting action is achieved through the cooperation of the reducer 7 and multiple sets of lead screws and nuts 8, ensuring that the brush plating functional unit can move accurately in the vertical direction. After completing the lifting action, the brush plating functional unit enters the working preparation state.

[0025] The brush plating unit is the core component of this device, and its structure and operating principle are as follows: Figure 4 As shown, the brush plating functional unit includes multiple brush plating heads 11, each corresponding to a different brush plating step.

[0026] S1: The PLC program drives the forward and backward mechanism to extend the first plating head 11 into the workpiece, simultaneously activating the electro-cleaning solution pump 12. The electro-cleaning solution pump 12 draws the electro-cleaning solution from the liquid storage tank 4 and circulates it. As the electro-cleaning solution flows towards the workpiece surface, the plating function circuit is activated. The current reversing system 13 sets the current direction to positive, and the voltage setting module 23 fixes the voltage at 10V. The current flows along the electro-cleaning solution tank 19 to remove ions from the workpiece surface, where impurities and ions precipitate and are periodically removed. The current module 22 monitors the current value in real time, which represents the ion movement speed. Based on previous experimental data, the PID calculation module 20 calculates the required ion flow rate using a PID calculus algorithm and outputs an analog signal to the electro-cleaning solution pump 12 to adjust the electro-cleaning solution flow rate, ensuring the ion flow rate is optimal. The system dynamically calculates the total ion volume based on the running time and uses the image monitoring system 14 to assist in determining whether this step is complete. The image monitoring system 14 captures changes in the surface condition of the workpiece in real time and transmits the image data to the PLC control system 15. The PLC control system 15 judges whether the plating effect meets the requirements based on the image analysis results.

[0027] S2: The PLC program drives the forward and backward mechanism to eject the first plating head 11 from the workpiece and drives the rotating mechanism to rotate by a preset angle, so that the second plating head 11 is in place. The rotating mechanism consists of a stepper motor 5, a transmission gear set 9, and an angle sensor 10, as follows: Figure 3 As shown. Angle sensor 10 is used to detect the rotation angle and feed the data back to PLC control system 15. PLC control system 15 precisely controls the rotation action according to the preset angle to ensure the accuracy of the brush plating head 11 switching process. After the second brush plating head 11 is in place, the next activation solution working stage begins.

[0028] During the brush plating process, the brush plating solution supply flow rate module 21 dynamically adjusts the supply flow rate of the brush plating solution according to the system algorithm to ensure that the effective components in the brush plating solution can uniformly cover the workpiece surface. The flow rate adjustment of the brush plating solution is achieved through the electro-cleaning pump 12, which receives analog signals from the PID calculation module 20 and adjusts the pump speed according to the signal magnitude. In addition, the current reversing system 13 can also dynamically adjust the current direction and magnitude according to the requirements of the brush plating steps, thereby adapting to the requirements of different brush plating processes. For example, in some steps, a reverse current is required to accelerate the deposition of specific ions, and the current reversing system 13 can quickly respond and complete the current direction switching.

[0029] The operating logic of this device demonstrates a high degree of intelligence and adaptability. For example, in the electro-cleaning step, the system adjusts the flow rate of the electro-cleaning solution by monitoring the current value in real time and combining it with a PID calculus algorithm, ensuring that the ion flow rate is always maintained at an optimal level. This dynamic control mechanism not only improves the brush plating efficiency but also significantly enhances the coating quality. Furthermore, the system algorithm, combined with real-time monitoring and database storage technology, further enhances the controllability and traceability of the brush plating process. After each brush plating operation, all relevant data, including workpiece dimensions, coating thickness, liquid concentration, and running time, are stored in database 25 for subsequent analysis and optimization.

[0030] The practical applications of this invention include, but are not limited to, the aerospace, automotive, and precision instrument manufacturing fields. For example, in the aerospace field, the surface treatment of engine blades requires extremely high precision and uniformity. Using the intelligent detection and adaptive control device for the brush plating machine of this invention, efficient brush plating of the blade surface can be achieved, ensuring uniform and defect-free coating thickness. In the automotive manufacturing field, the anti-corrosion treatment of body parts also requires high-quality coatings. This device significantly improves the corrosion resistance of parts by precisely controlling the coating thickness and liquid composition.

[0031] To sum up, the application realizes the accurate detection of workpiece size and dynamic regulation of coating thickness by integrating intelligent detection sensors, real-time control systems and multi-module collaborative driving mechanisms. The optimized brush plating function unit design and the cooperation of the multi-module collaborative driving mechanism make the brush plating process highly automated and accurate. Especially in the electric cleaning step, the PID integral algorithm dynamically regulates the flow rate of the electric cleaning liquid, ensuring that the ion flow rate is always in the best state, thereby significantly improving the efficiency and quality of brush plating. The system algorithm combines real-time monitoring and database storage technology, further enhancing the controllability and traceability of the brush plating process, meeting the needs of modern industrial production for efficient and accurate brush plating.

Claims

1. An intelligent detection and adaptive control device of a brush plating machine, comprising a workpiece size detection module (1, 2), a liquid concentration detection module (3, 4), a plating layer thickness input module, a current monitoring module (22), a PID integral algorithm flow control module (20), a forward and backward mechanism (5, 6), a lifting mechanism (5, 7, 8), a rotating mechanism (5, 9, 10) and a brush plating function unit (11, 12, 13), characterized in that the workpiece The size detection module (1, 2) is composed of an intelligent detection sensor (1) and a single-chip microcomputer (2), the intelligent detection sensor (1) is used for collecting the geometric parameters of the workpiece to be brushed and plated and transmitting the data to the single-chip microcomputer (2), and the single-chip microcomputer (2) calculates the total amount of copper ions required in the brushing and plating process based on a preset algorithm and stores the data in a database (25).

2. The intelligent detection and adaptive control device of the brush plating machine according to claim 1, characterized in that The liquid concentration detection module (3, 4) is arranged in a plurality of liquid storage pools (4), each liquid storage pool (4) is equipped with a concentration sensor (3), the concentration sensor (3) is used for real-time monitoring of the concentration of effective components in the brushing and plating liquid and transmitting the monitored data to the PLC control system (15).

3. The intelligent detection and adaptive control device of the brush plating machine according to claim 2, characterized in that The PID integral algorithm flow control module (20) calculates the required brushing and plating liquid flow by real-time monitoring of the current value and the brushing and plating liquid concentration data and converts the calculation result into the corresponding flow of the liquid inlet pump.

4. The intelligent detection and adaptive control device of the brush plating machine according to claim 1, characterized in that The forward and backward mechanism (5, 6) is composed of a stepping motor (5), a screw block assembly (6) and a PLC control system (15), the stepping motor (5) drives the screw block assembly (6) to drive the brushing and plating head (11) to extend into or exit the workpiece.

5. The intelligent detection and adaptive control device of the brush plating machine according to claim 4, characterized in that The lifting mechanism (5, 7, 8) is composed of a stepping motor (5), a speed reducer (7), a plurality of screw nuts (8) and a PLC control system (15), the stepping motor (5) realizes the accurate movement of the brushing and plating head (11) in the vertical direction through the cooperation of the speed reducer (7) and the plurality of screw nuts (8).

6. The intelligent detection and adaptive control device of the brush plating machine according to claim 1, characterized in that The rotating mechanism (5, 9, 10) is composed of a stepping motor (5), a transmission gear set (9) and an angle sensor (10), the stepping motor (5) drives the brushing and plating head (11) to switch through the transmission gear set (9), and the angle sensor (10) is used for detecting the rotation angle and feeding back the data to the PLC control system (15).

7. The intelligent detection and adaptive control device of the brush plating machine according to claim 1, characterized in that The plating layer thickness detection module (24) is used for real-time detection of the plating layer thickness during the brushing and plating process and feeding back the detection result to the PLC control system (15).

Images