Metal bar machining process control method and system

Abstract

The invention relates to the technical field of metal bar machining, and provides a metal bar machining process control method and system.The method comprises the steps that temperature difference data and flow data when a cooling medium flows through a drawing die are obtained, and a net heat flow value corresponding to the real-time heat state of the drawing die is determined according to the temperature difference data and the flow data; on the basis of the target machining state, a reference heat flow value is calibrated; and the deviation between the net heat flow value and the reference heat flow value is calculated, and the drawing speed is adjusted according to the deviation, so that the net heat flow value approaches the reference heat flow value, and the metal bar machining process is controlled. The problems that the temperature of the die is unstable due to fluctuation of heat production and heat dissipation, and then the dimensional accuracy of the bar is affected are solved, and the stability of the machining process and the product quality are remarkably improved.

Description

Technical Field

[0001] This invention relates to the technical field of metal rod processing, and specifically to a method and system for controlling the metal rod processing process. Background Technology

[0002] In the processing of metal bars, especially high-precision metal bars used in precision manufacturing, the multi-pass continuous drawing process to gradually reduce the diameter of the bar and improve its mechanical properties is a fundamental and core production technology. To ensure the consistency and accuracy of the final product dimensions, various process parameters, such as drawing speed, die tension, and cooling and lubrication conditions, need to be precisely controlled. In modern production management, cloud platforms are typically used to collect and analyze production data, and optimized process parameter instructions are issued based on the analysis results to guide the operation of local processing equipment.

[0003] However, a common technical challenge exists in translating cloud-based commands into actual production control: an information barrier exists between the global, environmental information held by the cloud and the local, process-oriented information perceived by the local device controller. Local controllers typically execute preset control programs based solely on their own state, such as accumulated processing length or set operating speed, remaining unaware of external environmental changes or fluctuations in the state of related systems that affect process stability. Therefore, they cannot combine the impending high-speed operation with the current poor external heat dissipation conditions—two crucial pieces of information—to make a predictive, non-linear parameter adjustment.

[0004] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0005] The purpose of this application is to provide a method and system for controlling the processing of metal bars. This method effectively solves the problem in the prior art where fluctuations in heat generation and dissipation cause unstable die temperature, which in turn affects the dimensional accuracy of the bars. It significantly improves the stability of the processing process and the quality of the products.

[0006] This application provides a method for controlling the processing of metal bars, including:

[0007] Acquire the temperature difference and flow rate data of the cooling medium as it flows through the drawing die, and determine the net heat flow value corresponding to the real-time thermal state of the drawing die based on the temperature difference and flow rate data.

[0008] Based on the target processing state, the reference heat flux value is calibrated;

[0009] The deviation between the net heat flow value and the reference heat flow value is calculated, and the drawing speed is adjusted according to the deviation to make the net heat flow value approach the reference heat flow value, so as to control the metal bar processing process.

[0010] The above solution effectively solves the problem of unstable mold temperature caused by heat generation and dissipation fluctuations, which affects the dimensional accuracy of the bar stock, by monitoring the thermal state of the mold in real time and dynamically adjusting the drawing speed. This improves the stability of the processing and the quality of the product.

[0011] Furthermore, this application also proposes that the step of calibrating the reference heat flux value based on the target processing state includes:

[0012] Receive calibration instructions;

[0013] After receiving the calibration command, acquire the product size measurement data and net heat flow value data corresponding to the target processing state;

[0014] Based on product size measurement data, determine whether the product size is within the target tolerance range corresponding to the target processing state within the first preset time period, and obtain the product size judgment result;

[0015] Based on the net heat flow value data, it is determined whether the rate of change of the net heat flow value data within the second preset time period is lower than the stable threshold, and the net heat flow value judgment result is obtained.

[0016] When both the product size determination result and the net heat flow value determination result are yes, the current net heat flow value data is determined as the baseline heat flow value.

[0017] The above scheme, by introducing a dual judgment mechanism of product size and net heat flux change rate, ensures the accuracy and reliability of the benchmark heat flux calibration and avoids calibration deviation caused by misjudgment due to a single factor.

[0018] Furthermore, this application also proposes a step for determining whether the rate of change of the net heat flux data within a second preset time period is lower than a stable threshold, based on the net heat flux data, to obtain the net heat flux determination result, including:

[0019] Obtain the processing task identifier of the current processing task;

[0020] Based on the processing task identifier, determine the stable threshold that matches the processing task identifier from the preset correspondence between stable thresholds and processing task identifiers;

[0021] Within the second preset time period, the rate of change of the net heat flow value is calculated, and it is determined whether the rate of change of the net heat flow value is lower than the matched stability threshold, so as to obtain the net heat flow value judgment result.

[0022] The above scheme dynamically matches stable thresholds for different processing tasks, making the judgment of net heat flux stability more flexible and accurate, and adapting to diverse production needs.

[0023] Furthermore, this application also proposes a step for controlling the metal bar processing process by calculating the deviation between the net heat flux value and the reference heat flux value, and adjusting the drawing speed according to the deviation to make the net heat flux value approach the reference heat flux value.

[0024] Obtain the drawing speed of the current processing step;

[0025] Based on the drawing speed, the control parameters that match the drawing speed are determined from the preset correspondence between the drawing speed range and the control parameters.

[0026] The deviation between the net heat flux value and the reference heat flux value is processed using control parameters to generate an adjustment amount for the drawing speed. The drawing speed is then adjusted according to the adjustment amount to make the net heat flux value approach the reference heat flux value, thereby controlling the metal bar processing process.

[0027] The above scheme achieves refined control of the drawing speed adjustment by dynamically determining the control parameters based on the current drawing speed, making the net heat flux value approach the reference heat flux value more quickly and accurately, thus improving the responsiveness and accuracy of the control.

[0028] Furthermore, this application also proposes a step of determining the control parameters matching the drawing speed from a preset correspondence between the drawing speed range and control parameters, based on the drawing speed:

[0029] Obtain the processing task identifier of the current processing task;

[0030] Based on the processing task identifier, select the correspondence that matches the processing task identifier from a number of preset drawing speed ranges and control parameters as the target correspondence.

[0031] Based on the current drawing speed, determine the control parameters in the target correspondence.

[0032] By adopting the above scheme, matching control parameter correspondences are selected for different processing tasks, the adjustment strategy of drawing speed is further optimized, and the adaptability and robustness of the control system are improved.

[0033] Furthermore, this application also proposes a step of processing the deviation between the net heat flux value and the reference heat flux value using control parameters to generate an adjustment amount for the drawing speed, including:

[0034] The component is adjusted proportionally based on the deviation between the net heat flux value and the reference heat flux value;

[0035] An integral adjustment component is generated based on the time integral of the deviation between the net heat flux value and the reference heat flux value;

[0036] The proportional adjustment component and the integral adjustment component are weighted using control parameters to obtain the weighted component.

[0037] The weighted components are combined to generate an adjustment for the drawing speed.

[0038] By employing the above scheme and weighting the proportional and integral adjustment components, the adjustment of the drawing speed becomes more precise and stable, effectively suppressing oscillations during the control process and improving the control effect.

[0039] Furthermore, this application also proposes a step for determining whether the product size is within the target tolerance range corresponding to the target processing state within a first preset time period based on product size measurement data, and obtaining the product size determination result, including:

[0040] Within the first preset time period, the product size measurement data are statistically processed to obtain the central statistical value and discrete statistical value;

[0041] Determine whether the central statistical value and the discrete statistical value meet the preset statistical conditions to obtain the product size judgment result.

[0042] By using the above method, statistical processing of product size measurement data and determination of whether statistical conditions are met, it is possible to more comprehensively and accurately assess whether product size is within the target tolerance range, thereby improving the reliability of calibration reference heat flux values.

[0043] Furthermore, this application also proposes a step for determining the net heat flux value corresponding to the real-time thermal state of the drawing die based on temperature difference data and flow rate data, including:

[0044] Obtain the state parameters corresponding to the current physical state of the cooling medium;

[0045] Based on the state parameters, determine the physical characteristic parameters that match the state parameters from the preset correspondence between physical characteristic parameters and state parameters;

[0046] The net heat flux value is determined based on temperature difference data, flow rate data, and physical characteristic parameters.

[0047] By considering the physical properties of the cooling medium, the above scheme makes the determination of the net heat flux more accurate, providing a more reliable data basis for subsequent process control.

[0048] Furthermore, this application also proposes that the steps for obtaining the state parameters corresponding to the current physical state of the cooling medium include:

[0049] Obtain the first state parameter corresponding to the first physical quantity of the cooling medium;

[0050] Obtain the second state parameter corresponding to the second physical quantity of the cooling medium;

[0051] The state parameters are determined based on the first state parameter and the second state parameter.

[0052] By using the above scheme and obtaining the state parameters corresponding to multiple physical quantities of the cooling medium, the current physical state of the cooling medium can be characterized more comprehensively, further improving the accuracy of determining the net heat flux value.

[0053] Furthermore, this application also proposes a metal bar processing control system for performing metal bar processing control, comprising:

[0054] The net heat flux determination module is used to acquire the temperature difference data and flow rate data of the cooling medium when it flows through the drawing die, and to determine the net heat flux value corresponding to the real-time thermal state of the drawing die based on the temperature difference data and flow rate data.

[0055] The reference heat flux calibration module is used to calibrate the reference heat flux value based on the target processing state;

[0056] The drawing speed control module is used to calculate the deviation between the net heat flow value and the reference heat flow value, and adjust the drawing speed according to the deviation so that the net heat flow value approaches the reference heat flow value, thereby controlling the metal bar processing process.

[0057] The above scheme provides a system implementation plan that can effectively execute the above method, providing hardware and software support for the automation and intelligent control of metal bar processing.

[0058] As can be seen from the above, the metal bar processing control method and system provided in this application effectively solves the problem of unstable die temperature caused by heat generation and heat dissipation fluctuations in the prior art, which in turn affects the dimensional accuracy of the bar, by real-time monitoring of the thermal state of the drawing die and dynamic adjustment of the drawing speed, and significantly improves the stability of the processing process and product quality. Attached Figure Description

[0059] Figure 1 This is a flowchart of a method for controlling the processing of metal rods according to one embodiment of the present invention;

[0060] Figure 2 This is one of the flowcharts of a method for controlling the processing of metal rods according to another embodiment of the present invention;

[0061] Figure 3 This is a second flowchart of a method for controlling the processing of metal rods according to another embodiment of the present invention;

[0062] Figure 4 This is a third flowchart of a method for controlling the processing of metal rods according to another embodiment of the present invention;

[0063] Figure 5 This is the fourth flowchart of a method for controlling the processing of metal rods according to another embodiment of the present invention;

[0064] Figure 6 This is the fifth flowchart of a method for controlling the processing of metal rods according to another embodiment of the present invention;

[0065] Figure 7 This is a flowchart of a method for controlling the processing of metal rods according to another embodiment of the present invention;

[0066] Figure 8 This is the seventh flowchart of a method for controlling the processing of metal rods according to another embodiment of the present invention;

[0067] Figure 9 This is the eighth flowchart of a method for controlling the processing of metal rods according to another embodiment of the present invention;

[0068] Figure 10 This is a system block diagram of a metal bar processing control system according to another embodiment of the present invention.

[0069] Explanation of reference numerals in the attached figures:

[0070] 1. Metal bar processing control system; 11. Net heat flow value determination module; 12. Reference heat flow calibration module; 13. Drawing speed control module. Detailed Implementation

[0071] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, and not all embodiments. The components of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0072] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, terms such as "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0073] In traditional multi-pass continuous drawing production of metal bars, controlling the finished product diameter presents the challenge of obtaining thermodynamic boundary conditions such as external ambient temperature and the status of the central cooling system from local processing equipment. This results in the finished product diameter being simultaneously affected by both nonlinear wear of the temperature-sensitive die and real-time thermal expansion. Furthermore, the operating temperature is jointly determined by the internally variable drawing speed and the efficiency of the cooling system, which is influenced by the external environment. Consequently, the final finished product diameter exhibits irregular fluctuations, making it difficult to stabilize it within the micrometer-level tolerance range.

[0074] For example, suppose a manufacturing workshop produces special copper alloy rods for precision electronic component pins. The core equipment is a multi-pass, tandem high-speed drawing machine. This machine continuously draws a 5mm diameter raw copper rod through twelve cemented carbide dies to a diameter of 1mm, with the final diameter tolerance strictly limited to ±2 micrometers. The drawing process is a heat-generating process, and the rate of heat generation is directly related to the drawing speed. When the drawing speed increases, the heat generation power increases significantly; conversely, when heat generation is interrupted, the die temperature drops rapidly. Simultaneously, the cooling and lubrication system exchanges heat with the atmosphere through a heat exchanger. Its heat dissipation capacity is affected by the external ambient temperature; for example, high daytime temperatures in summer reduce heat dissipation efficiency, while low nighttime temperatures increase it. The superposition of these two independent thermodynamic variables causes fluctuations in the actual operating temperature of the die. The die wear process is temperature-sensitive, with a faster wear rate at higher operating temperatures. The die itself also exhibits thermal expansion and contraction; as the temperature rises, the inner hole contracts due to thermal expansion, resulting in a thinner drawn rod diameter. The local controller only compensates based on the cumulative processing length and cannot sense the external temperature and the operating efficiency of the central cooling system, which prevents it from combining high-speed operation with external heat dissipation conditions to adjust parameters.

[0075] In response, this application proposes a method for controlling the processing of metal bars, combining... Figure 1 As shown, it includes:

[0076] S1, acquire the temperature difference data and flow rate data of the cooling medium when it flows through the drawing die, and determine the net heat flow value corresponding to the real-time thermal state of the drawing die based on the temperature difference data and flow rate data;

[0077] S2, based on the target processing state, calibrates the reference heat flux value;

[0078] S3 calculates the deviation between the net heat flow value and the reference heat flow value, and adjusts the drawing speed according to the deviation to make the net heat flow value approach the reference heat flow value, so as to control the metal bar processing process.

[0079] The temperature difference data of the cooling medium flowing through the drawing die refers to the temperature difference between the cooling medium before entering the drawing die area and after leaving the area. This can be achieved using a high-precision temperature sensor array or a distributed fiber optic temperature measurement system, such as placing thermocouples or resistance thermometers at the coolant inlet and outlet. Its main purpose is to obtain quantitative information on the heat exchange between the die area and the cooling medium. The flow rate data refers to the volume or mass of the cooling medium flowing through the drawing die area per unit time. This can be achieved using a high-precision turbine flow meter, electromagnetic flow meter, or ultrasonic flow meter, such as installing a flow sensor in the coolant circulation pipeline. Its main purpose is to accurately calculate the heat carried away by the cooling medium. The net heat flux value refers to the net heat exchange rate between the internal heat generation and external heat dissipation of the drawing die under real-time operating conditions. It can be determined based on the temperature difference data, flow rate data, and physical property parameters of the cooling medium (such as specific heat capacity and density) through a thermodynamic calculation model. Its main purpose is to quantify the real-time thermal balance state of the die, serving as a basis for subsequent control. The target processing state refers to the desired product quality standard that the metal bar is expected to achieve during the drawing process, such as a specific diameter tolerance range, surface roughness, or mechanical performance indicators. This can be pre-set by the production process engineer based on product application requirements, primarily to provide a target and control benchmark for the processing. The reference heat flux value refers to the heat flux value that the drawing die should maintain when the metal bar reaches the target processing state. It can be calculated based on historical production data, experimental calibration, or theoretical models, mainly to provide a reference target for real-time net heat flux values ​​for deviation comparison and control. Adjusting the drawing speed refers to influencing the heat generation rate during the drawing process by changing the operating speed of the drawing machine. This can be achieved by using a frequency converter to control the motor speed or by hydraulic system flow control, primarily to dynamically adjust the thermal load of the die as a control variable to maintain thermal balance.

[0080] To achieve the above objectives, the proposed solution effectively addresses the temperature fluctuation problem caused by multiple factors coupled during the drawing process of metal bars by establishing a closed-loop feedback control mechanism based on the thermal state of the die. First, by acquiring real-time temperature difference and flow rate data of the cooling medium flowing through the drawing die, the heat exchange between the die and the cooling medium can be accurately captured. Given the physical properties of the cooling medium, these data are used to determine the net heat flux value corresponding to the real-time thermal state of the drawing die. This net heat flux value comprehensively reflects the heat generated inside the die due to plastic deformation and friction, as well as the heat removed by the external cooling system, thus indirectly and accurately characterizing the actual working temperature and thermal equilibrium state of the die, avoiding the limitations of directly measuring the die temperature. Based on this, the solution further calibrates a reference heat flux value based on a preset target processing state, such as the desired bar diameter tolerance. This reference heat flux value represents the thermal equilibrium point that the die should maintain under target, stable processing conditions. Subsequently, the system continuously calculates the deviation between the real-time acquired net heat flux value and this reference heat flux value. The existence of this deviation indicates that the current processing thermal state deviates from the target state. Therefore, the system dynamically adjusts the drawing speed according to the calculated deviation. Adjusting the drawing speed directly affects the amount of metal bar passing through the die per unit time and the rate of frictional heat generation, thus altering the die's thermal load. In this way, the drawing speed is precisely adjusted, causing the die's net heat flux to gradually approach a preset baseline heat flux value. This continuous feedback adjustment mechanism ensures that the drawing die always operates in a thermal equilibrium state close to the target.

[0081] In some preferred embodiments, this application is implemented as follows. On a metal bar drawing production line, high-precision temperature sensors, such as platinum resistance thermometers, can be installed at the inlet and outlet of the cooling medium of the drawing die to obtain temperature difference data of the cooling medium. Simultaneously, a high-precision flow sensor, such as a Coriolis mass flow meter, is installed in the circulation pipeline of the cooling medium to obtain flow data. The data from these sensors can be transmitted in real time to an industrial controller, such as a programmable logic controller (PLC) or a distributed control system (DCS). This controller integrates a calculation module that can determine the net heat flow value of the drawing die in real time based on the physical properties of the cooling medium, such as its specific heat capacity and density, combined with real-time temperature difference data and flow data, using a thermodynamic formula (e.g., Q = m * c * ΔT, where Q is the net heat flow value, m is the mass flow rate, c is the specific heat capacity, and ΔT is the temperature difference). For example, when producing metal bars of a specific specification, the operator or the upper control system can set a target processing state, such as a finished product diameter of 1.000 mm and a tolerance range of ±2 micrometers. In the initial stages of production, once the product dimensions have been inspected and confirmed to be stable within the target tolerance range, the system receives a calibration command. At this point, the real-time net heat flux value is recorded and designated as the baseline heat flux value. Specifically, the industrial controller continuously calculates the deviation between the real-time net heat flux value and the calibrated baseline heat flux value. For example, if the real-time net heat flux value is higher than the baseline heat flux value, it indicates that the mold temperature is too high; if it is lower than the baseline heat flux value, it indicates that the mold temperature is too low. The controller's internal control algorithm, such as a proportional-integral-derivative (PID) controller, generates an adjustment amount for the drawing speed based on this deviation. This adjustment amount is then sent to the frequency converter or servo drive system of the drawing machine to precisely adjust the speed of the drawing motor, thereby changing the drawing speed. Through this closed-loop control, when the net heat flux value is too high, the drawing speed is appropriately reduced to decrease heat generation; when the net heat flux value is too low, the drawing speed is appropriately increased to increase heat generation. This dynamic adjustment ensures that the mold's net heat flux value always approaches the baseline heat flux value, thus maintaining the mold's operating temperature.

[0082] Optional, combined Figure 2 As shown, the steps of S2 in calibrating the reference heat flux value based on the target processing state include:

[0083] S21, Receive calibration command;

[0084] S22, after receiving the calibration command, acquires the product size measurement data and net heat flow value data corresponding to the target processing state;

[0085] S23, Based on the product size measurement data, determine whether the product size is within the target tolerance range corresponding to the target processing state within the first preset time period, and obtain the product size judgment result;

[0086] S24, Based on the net heat flow value data, determine whether the rate of change of the net heat flow value data within the second preset time period is lower than the stable threshold, and obtain the net heat flow value judgment result;

[0087] S25, when the product size judgment result is yes and the net heat flow value judgment result is yes, the current net heat flow value data is determined as the reference heat flow value.

[0088] The calibration command refers to the signal or command used to initiate the calibration process of the reference heat flux value. It can be manually input by the operator or automatically triggered by the automated system based on preset conditions. Its purpose is to initiate the determination of the reference value at a specific time. The target processing state refers to the ideal production conditions expected to be achieved during the metal bar processing, including specific product dimensions, surface quality, mechanical properties, and other requirements. Its purpose is to provide a reference standard for determining the reference heat flux value. Product dimension measurement data refers to the geometric dimension information of the metal bar, such as diameter and cross-sectional shape, acquired in real-time or periodically by measuring equipment. This can be obtained using laser diameter gauges, eddy current sensors, or contact measuring devices. Its purpose is to reflect whether the currently processed product meets the dimensional requirements. Net heat flux data refers to the calculated heat exchange rate in the drawing die area at a specific point in time or within a specific time period. It can be calculated from the temperature difference and flow rate data of the cooling medium. Its purpose is to reflect the real-time thermal state of the drawing die. The first preset duration refers to the time window used to evaluate the stability of product dimensions. It can be set according to the response speed of the processing technology and the characteristics of dimensional fluctuations. The purpose is to ensure that product dimensions remain stable over a period of time. The target tolerance range refers to the allowable deviation range of product dimensions under the target processing condition. It can be determined based on product design requirements or industry standards. Its purpose is to define the acceptable range for product dimensions. The second preset duration refers to the time window used to evaluate the stability of the net heat flux value. It can be set based on the thermal system response speed and heat flux fluctuation characteristics. Its purpose is to ensure that the net heat flux value remains stable over a period of time. The stability threshold refers to the upper limit used to determine whether the rate of change of the net heat flux value data is in a stable state. It can be preset according to different processing tasks or material characteristics. Its purpose is to quantify the degree of fluctuation in the net heat flux value.

[0089] In some preferred embodiments, this application is implemented as follows: When an operator issues a calibration command on the control terminal, for example by clicking the "Start Reference Calibration" button on the graphical user interface, the system begins to execute the calibration process for the reference heat flux value. Upon receiving the command, the system immediately initiates data acquisition to obtain the product size measurement data on the current production line. This data can be provided in real time by an online laser diameter gauge installed at the drawing die exit. Simultaneously, the system acquires the net heat flux value data of the drawing die cooling circuit, which can be calculated by the inlet and outlet temperature sensors and flow sensors of the cooling medium. Specifically, the system continuously monitors whether the product size measurement data remains within the target tolerance range corresponding to the target processing state within a first preset time period, such as 30 seconds. For example, if the target diameter is 1.000 mm and the target tolerance range is ±0.002 mm, the system determines whether all measured diameter values ​​within these 30 seconds are between 0.998 mm and 1.002 mm. Simultaneously, the system also continuously calculates the rate of change of the net heat flux value data within a second preset time period, such as 60 seconds, and determines whether it is below a preset stability threshold. For example, the change in net heat flux per second can be calculated. If the change per second is less than a certain value for 60 consecutive seconds, the net heat flux is considered to be in a stable state. Only when both conditions are met—that is, the product dimensions remain within acceptable limits for a first preset time period, and the net heat flux remains stable for a second preset time period—will the system determine the current net heat flux data, or the average net heat flux value over that stable period, as the baseline heat flux value. This determined baseline heat flux value will then be stored and used for subsequent drawing speed control, serving as the target heat flux value for deviation calculation.

[0090] Optional, combined Figure 3 As shown, S24, based on the net heat flux data, determines whether the rate of change of the net heat flux data within a second preset time period is lower than a stable threshold, and obtains the net heat flux judgment result by including:

[0091] S241, Obtain the processing task identifier of the current processing task;

[0092] S242, Based on the processing task identifier, determine the stable threshold that matches the processing task identifier from the preset correspondence between stable thresholds and processing task identifiers;

[0093] S243, within the second preset time period, calculate the rate of change of net heat flow data, and determine whether the rate of change of net heat flow data is lower than the matched stability threshold, and obtain the net heat flow judgment result.

[0094] The processing task identifier refers to information used to uniquely identify or classify the currently executing processing task. It can be a string, numeric code, or other data format, and its purpose is to distinguish different types or requirements of processing tasks, thus providing a basis for subsequent parameter selection. The preset correspondence between the stability threshold and the processing task identifier refers to a pre-established data structure or set of rules that associates a specific processing task with a corresponding heat flux stability threshold. This can be a lookup table, database record, or a set of conditional judgment logic, and its purpose is to dynamically select an appropriate stability threshold based on the characteristics of the current processing task. The matched stability threshold refers to the heat flux stability judgment standard applicable to the current processing task, retrieved or calculated from the preset correspondence based on the current processing task identifier. Its purpose is to ensure the accuracy and adaptability of the heat flux stability judgment to meet the differentiated requirements of different processing tasks for heat flux stability.

[0095] In some preferred embodiments, this application is implemented as follows. Assume a metal rod processing workshop with various processing tasks, such as producing thin rods for precision electronic components (Task A) and producing thick rods for building structures (Task B). These tasks have significantly different requirements for the thermal flow stability of the drawing dies. To achieve dynamic stability threshold management, the system first obtains the processing task identifier of the currently executing processing task. For example, if the current processing task is producing precision electronic component pins, the obtained processing task identifier could be "precision pin processing". Next, the system queries a preset database or lookup table based on the "precision pin processing" identifier. This database pre-stores the association between different processing task identifiers and corresponding stability thresholds. For example, for the "precision pin processing" task, its corresponding stability threshold can be set to 0.05 W / s; while for the "building structure rod processing" task, its corresponding stability threshold can be set to 0.2 W / s. Through the query, the system determines that the stability threshold matching the "precision pin processing" identifier is 0.05 W / s. Subsequently, within a second preset time period, for example, within the most recent 60 seconds, the system continuously collects net heat flux data and calculates the rate of change of this data. The rate of change can be calculated using various methods; for example, it can calculate the average absolute change in net heat flux per second, or fit the slope of the net heat flux change over time using linear regression analysis. Assume the calculated rate of change of net heat flux data is 0.03 W / s. The system compares this calculated result of 0.03 W / s with a matched stability threshold of 0.05 W / s. Since 0.03 W / s is lower than 0.05 W / s, the system determines that the net heat flux data is stable, thus obtaining a net heat flux judgment result of "yes". This judgment result will be used for subsequent baseline heat flux value calibration, ensuring that the baseline heat flux value is determined only when the heat flux state meets the stringent requirements of the current precision machining task.

[0096] Optional, combined Figure 4 As shown, S3 calculates the deviation between the net heat flux value and the reference heat flux value, and adjusts the drawing speed according to the deviation to make the net heat flux value approach the reference heat flux value. The steps for controlling the metal bar processing include:

[0097] S31, obtain the drawing speed of the current processing step;

[0098] S32, Based on the drawing speed, determine the control parameters that match the drawing speed from the preset correspondence between the drawing speed range and the control parameters;

[0099] S33 uses control parameters to process the deviation between the net heat flux value and the reference heat flux value, generates an adjustment amount for the drawing speed, and adjusts the drawing speed according to the adjustment amount to make the net heat flux value approach the reference heat flux value, thereby controlling the metal bar processing process.

[0100] The correspondence between the drawing speed range and the control parameters refers to a pre-established mapping relationship that associates different drawing speed ranges with one or more sets of control parameters. This mapping relationship can be implemented using lookup tables, piecewise functions, or rule-based logic. Its purpose is to dynamically select an appropriate control strategy based on the current drawing speed. The control parameters are a set of values ​​used to handle the deviation between the net heat flux value and the reference heat flux value. These parameters can include proportional coefficients, integral coefficients, derivative coefficients, etc., and their purpose is to influence the response characteristics and stability of the deviation handling. The adjustment amount is a value calculated based on the deviation and control parameters to change the current drawing speed. It can be an increment or a decrement, and its purpose is to guide the drawing speed to converge toward the target state.

[0101] In some preferred embodiments, this application is implemented as follows: First, the control system can acquire the current drawing speed of the drawing machine in real time, for example, through a speed sensor installed on the drawing machine. Then, the system can query a pre-stored lookup table, which records different drawing speed ranges and the corresponding set of control parameters for each range. For example, when the drawing speed is in the low-speed range, a more conservative set of proportional-integral-derivative (PID) control parameters can be used; when the drawing speed is in the high-speed range, a more aggressive or faster-responding set of PID control parameters can be used. Based on the currently acquired drawing speed, the system finds the corresponding drawing speed range in the lookup table and extracts the corresponding control parameters. Next, the system uses these extracted control parameters to perform PID algorithm processing on the deviation between the current net heat flux value and the reference heat flux value, calculating an adjustment amount for the drawing speed. For example, if the deviation is large and the drawing speed is fast, the system can calculate a large negative adjustment amount based on the control parameters corresponding to the current speed to quickly reduce the drawing speed. Finally, the system sends this adjustment to the speed controller of the drawing machine, which then adjusts the drawing speed to gradually bring the net heat flux value closer to the reference heat flux value, thus maintaining the stability of the processing.

[0102] Optional, combined Figure 5 As shown, the step S32, which determines the control parameters matching the drawing speed from the preset correspondence between the drawing speed range and the control parameters, includes:

[0103] S321, Obtain the processing task identifier of the current processing task;

[0104] S322, Based on the processing task identifier, select the correspondence that matches the processing task identifier from a number of preset correspondences between drawing speed ranges and control parameters as the target correspondence;

[0105] S323, determine the control parameters in the target correspondence based on the current drawing speed.

[0106] The processing task identifier is information used to uniquely identify the type or characteristics of the current metal bar processing task. It can be represented by a string, numeric code, hash value, or predefined enumeration value. For example, it could be a code representing the bar material, final diameter specification, or a specific customer order number. Its purpose is to differentiate between different processing requirements and provide a basis for selecting appropriate control strategies. The preset correspondence between several drawing speed ranges and control parameters refers to a set of pre-stored lookup tables or function models of control parameters customized for different processing tasks or process conditions. These can be stored and managed using database tables, configuration files, multidimensional arrays, or machine learning models. Each correspondence includes a mapping between drawing speed ranges and corresponding control parameters, aiming to provide customized control strategies for different processing tasks to adapt to diverse production needs. The target correspondence refers to the mapping relationship between the specific drawing speed range and the control parameters that are most suitable for the current processing task, selected or filtered from several preset correspondence relationships based on the current processing task identifier. It can be a pointer to a specific data table, a path to a configuration file, or an activated function model. Its purpose is to ensure that the subsequent control parameter determination process is based on the specific needs and optimization goals of the current processing task.

[0107] In some preferred embodiments, this application is implemented as follows. Assume the metal rod processing system needs to handle two main processing tasks: one is the production of high-precision copper alloy rods, and the other is the production of standard aluminum alloy rods. The system can pre-store two sets of correspondences between drawing speed ranges and control parameters. The first set of correspondences is specifically optimized for the processing characteristics of copper alloy rods. For example, at a drawing speed of 800-1000 m / min, it may correspond to one set of PID control parameters; at a drawing speed of 1000-1200 m / min, it corresponds to another set of parameters. The second set of correspondences is optimized for the processing characteristics of aluminum alloy rods, and its parameter settings may differ from those for copper alloy rods. For example, within the same drawing speed range, it may correspond to different PID parameter values. When an operator starts a new processing task, the system first obtains the processing task identifier of the current processing task. For example, if the operator selects the "copper alloy rod production" task, the system will obtain the corresponding processing task identifier, such as "TASK_CU_HIGH_PRECISION". Subsequently, the control system retrieves and selects the first set of correspondences matching the "TASK_CU_HIGH_PRECISION" identifier from a pre-set correspondence database based on this identifier, and sets it as the current target correspondence. During processing, if the current drawing speed is 950 m / min, the system will search or interpolate the control parameters matching the drawing speed of 950 m / min from the established first set of target correspondences. These parameters are then used to calculate the adjustment amount of the drawing speed. If the processing task is switched to "aluminum alloy bar production", the system will obtain the "TASK_AL_STANDARD" identifier and automatically switch to the second set of correspondences as the target correspondence, thereby ensuring that the subsequent selection of control parameters is based on the processing characteristics of aluminum alloy.

[0108] Optional, combined Figure 6 As shown, the steps in S33 for processing the deviation between the net heat flux value and the reference heat flux value using control parameters to generate the adjustment amount for the drawing speed include:

[0109] S331, generates a proportional adjustment component based on the deviation between the net heat flow value and the reference heat flow value;

[0110] S332, generates an integral adjustment component based on the time integral of the deviation between the net heat flux value and the reference heat flux value;

[0111] S333 uses control parameters to weight the proportional adjustment component and the integral adjustment component to obtain the weighted component.

[0112] S334 combines the weighted components to generate the adjustment amount for the drawing speed.

[0113] The proportional adjustment component refers to the adjustment portion directly generated based on the current magnitude of the deviation between the net heat flux value and the reference heat flux value. It can be achieved by multiplying the deviation value by a proportional coefficient, aiming to provide an immediate response to the deviation and quickly correct the drawing speed. The integral adjustment component refers to the adjustment portion generated based on the cumulative effect of the deviation between the net heat flux value and the reference heat flux value over a period of time. It can be achieved by integrating the deviation value over time, aiming to eliminate potential steady-state errors in the system and improve the long-term accuracy of control. Weighted processing refers to adjusting the degree of influence of different adjustment components according to preset weighting factors. It can be achieved by multiplying each adjustment component by its corresponding weighting coefficient, aiming to dynamically adjust the contribution of each component to the total adjustment based on actual operating conditions. Combination refers to merging the weighted components. It can be achieved by summing the weighted proportional adjustment component and the integral adjustment component, aiming to form a comprehensive drawing speed adjustment command.

[0114] In some preferred embodiments, the deviation between the net heat flux value and the reference heat flux value is processed using control parameters to generate the adjustment amount of the drawing speed. This can be specifically implemented as follows: First, the system obtains the deviation between the net heat flux value and the reference heat flux value (denoted as Error). Next, a proportional adjustment component is generated, for example, by multiplying Error by a preset proportional gain Kp, i.e., ProportionalComponent = Kp * Error. Simultaneously, an integral adjustment component is generated, for example, by integrating Error over a period of time and multiplying it by a preset integral gain Ki, i.e., IntegralComponent = Ki * Integral(Error)dt. Subsequently, these components are weighted using control parameters determined from the correspondence between preset drawing speed ranges and control parameters. Assuming the obtained control parameters contain two weight values, such as Wp and Wi, corresponding to the proportional adjustment component and the integral adjustment component, respectively, then the weighted components can be expressed as WeightedProportional = Wp * ProportionalComponent and WeightedIntegral = Wi * IntegralComponent. Finally, these weighted components are combined, for example by simple addition, to generate the final adjustment amount for the drawing speed: SpeedAdjustment = WeightedProportional + WeightedIntegral. In this way, the system can dynamically adjust Wp and Wi according to the current drawing speed and processing task, thereby flexibly controlling the contribution of the proportional and integral responses to the total adjustment amount, ensuring accurate tracking of the net heat flux and stable regulation of the drawing speed under different operating conditions.

[0115] Optional, combined Figure 7 As shown, step S23, based on product size measurement data, determines whether the product size is within the target tolerance range corresponding to the target processing state within a first preset time period, and obtains the product size determination result, including:

[0116] S231, within a first preset time period, perform statistical processing on the product size measurement data to obtain central statistical values ​​and discrete statistical values;

[0117] S232, determine whether the central statistical value and the discrete statistical value meet the preset statistical conditions, and obtain the product size judgment result.

[0118] Among them, the central statistic refers to a measure that reflects the central tendency of a set of data, specifically the mean, median, or mode, and its purpose is to characterize the overall level of product size over a period of time; the discrete statistic refers to a measure that reflects the degree of fluctuation of a set of data, specifically the standard deviation, variance, or range, and its purpose is to characterize the stability or consistency of product size over a period of time; the preset statistical conditions refer to the criteria used to evaluate whether product size meets specific quality requirements, specifically the thresholds or ranges set for the central and discrete statistics respectively, and their purpose is to ensure that product size not only meets the target range but also has acceptable stability.

[0119] In some preferred embodiments, specifically, diameter measurement data of the metal rod can be continuously collected within a first preset time period. For example, diameter data is collected at fixed time intervals, and after the first preset time period ends, statistical analysis is performed on all diameter data collected during that period. The central statistic can be specifically calculated as the arithmetic mean of these diameter measurements to reflect the average level of the product diameter during that period. The discrete statistic can be specifically calculated as the standard deviation of these diameter measurements to reflect the degree of fluctuation in the product diameter during that period. Subsequently, the system can determine whether the calculated average value is within a specific allowable deviation range of the target size and whether the standard deviation is lower than a preset stability threshold. Only when both the average value and the standard deviation meet these preset conditions is the product size considered stable and qualified, and the corresponding product size judgment result is output.

[0120] Optional, combined Figure 8 As shown, the steps in S1 for determining the net heat flux value corresponding to the real-time thermal state of the drawing die based on temperature difference data and flow rate data include:

[0121] S11, Obtain the state parameters corresponding to the current physical state of the cooling medium;

[0122] S12, Based on the state parameters, determine the physical characteristic parameters that match the state parameters from the preset correspondence between physical characteristic parameters and state parameters;

[0123] S13 determines the net heat flux value based on temperature difference data, flow rate data, and physical characteristic parameters.

[0124] Among them, the state parameters corresponding to the current physical state of the cooling medium refer to a series of quantitative indicators that reflect the physical conditions of the cooling medium at a specific moment. Specifically, these can be the temperature, pressure, density, flow rate, or component concentration of the cooling medium. The purpose is to comprehensively capture the real-time state of the cooling medium and provide a basis for subsequent accurate calculation of its physical properties.

[0125] The pre-defined correspondence between physical characteristic parameters and state parameters refers to the mapping relationship established before or during system operation through experiments, theoretical calculations, or table lookups, describing how the physical characteristic parameters of the cooling medium change with its state parameters. Specifically, it can be achieved through lookup tables stored in a database, pre-defined mathematical models, or empirical formulas. Its purpose is to dynamically obtain the accurate physical characteristics of the cooling medium based on its real-time state, so as to improve the accuracy of net heat flux calculation.

[0126] Physical property parameters refer to the inherent thermodynamic properties exhibited by a cooling medium under specific physical conditions. Specifically, these can be the specific heat capacity, density, thermal conductivity, or viscosity of the cooling medium. Their purpose is to accurately reflect the heat transfer and absorption capacity of the cooling medium under the current conditions.

[0127] In some preferred embodiments, determining the net heat flux value corresponding to the real-time thermal state of the drawing die can be specifically implemented as follows:

[0128] First, obtain the state parameters corresponding to the current physical state of the cooling medium. For example, temperature sensors and pressure sensors can be installed at the inlet and outlet of the cooling medium, respectively, to collect the inlet temperature, outlet temperature, inlet pressure, and outlet pressure of the cooling medium in real time, and use these temperature and pressure data as state parameters.

[0129] Next, based on the state parameters, the system determines the physical characteristic parameters that match the state parameters from a pre-defined correspondence between physical characteristic parameters and state parameters. For example, a lookup table or mathematical model containing physical characteristic parameters such as specific heat capacity and density of the cooling medium at different temperatures and pressures can be pre-established. Once the current temperature and pressure state parameters of the cooling medium are obtained, the system can query the lookup table or use the mathematical model to interpolate or calculate the precise specific heat capacity and density of the cooling medium at the current temperature and pressure.

[0130] Finally, the net heat flux is determined based on temperature difference data, flow rate data, and these dynamically determined physical property parameters. For example, the net heat flux can be calculated using the modified heat calculation formula Q = ρ * V * c * ΔT, where ρ is the density of the cooling medium determined based on the current state parameters, V is the flow rate data, c is the specific heat capacity of the cooling medium determined based on the current state parameters, and ΔT is the temperature difference data. In this way, the calculation of the net heat flux fully considers the actual situation of the physical properties of the cooling medium changing with the state, thus obtaining a more accurate assessment of the mold's thermal state.

[0131] Optional, combined Figure 9 As shown, the steps in S11 for obtaining the state parameters corresponding to the current physical state of the cooling medium include:

[0132] S111, Obtain the first state parameter corresponding to the first physical quantity of the cooling medium;

[0133] S112, Obtain the second state parameter corresponding to the second physical quantity of the cooling medium;

[0134] S113, determine the state parameters based on the first state parameter and the second state parameter.

[0135] Here, the first physical quantity refers to a measurable physical property of the cooling medium, which can be realized using physical properties such as temperature, pressure, density, viscosity, or flow rate; the first state parameter refers to the real-time measured or calculated value corresponding to the first physical quantity of the cooling medium, which can be directly acquired by sensors or obtained through other data processing; the second physical quantity refers to another measurable physical property of the cooling medium, which is different from the first physical quantity, and can be realized using physical properties such as pressure, density, viscosity, or flow rate; the second state parameter refers to the real-time measured or calculated value corresponding to the second physical quantity of the cooling medium, which can be directly acquired by sensors or obtained through other data processing; the state parameter refers to one or a set of values ​​that comprehensively reflect the current thermodynamic characteristics of the cooling medium, which can be determined by fusing multiple independent physical quantity parameters using methods such as function calculation, lookup table method, or machine learning model, with the aim of providing a more comprehensive and accurate description of the cooling medium's state to support subsequent heat flux calculations.

[0136] This application's solution goes beyond characterizing the physical state of the cooling medium with a single physical quantity, simultaneously acquiring the state parameters corresponding to two independent physical quantities of the cooling medium. For example, temperature and pressure data of the cooling medium can be acquired simultaneously. Because the physical properties of the cooling medium, such as specific heat capacity, density, and viscosity, are not solely functions of temperature but are also affected by pressure, relying solely on temperature data to deduce its thermodynamic properties has limitations. By introducing a second physical quantity, such as pressure, the true thermodynamic behavior of the cooling medium under different operating conditions can be captured more comprehensively. Based on this, and using the acquired first and second state parameters, the system can comprehensively determine a more representative state parameter through preset logic or models. This multi-parameter fusion approach allows the determined state parameter to more accurately reflect the real-time thermodynamic properties of the cooling medium, such as its actual specific heat capacity or thermal conductivity at the current temperature and pressure. Because more accurate cooling medium state parameters are obtained, the physical property parameters used to determine the net heat flux value corresponding to the real-time thermal state of the drawing die based on temperature difference and flow rate data will be closer to reality, thus significantly improving the accuracy of the net heat flux value calculation. This improvement allows for more precise monitoring of the thermal state of the drawing die, providing a more reliable basis for subsequent drawing speed adjustments, thereby effectively suppressing fluctuations in the finished product diameter and ensuring processing accuracy.

[0137] In some preferred embodiments, obtaining the state parameters corresponding to the current physical state of the cooling medium can be implemented as follows: First, the temperature value of the cooling medium is acquired in real time using temperature sensors installed at the inlet and / or outlet of the cooling medium, serving as the first state parameter corresponding to the first physical quantity of cooling medium temperature. Simultaneously, the pressure value of the cooling medium is acquired in real time using pressure sensors installed in the cooling medium circulation pipeline, serving as the second state parameter corresponding to the second physical quantity of cooling medium pressure. Subsequently, based on the acquired temperature and pressure values, the system can determine the comprehensive state parameters of the cooling medium under the current operating conditions using a pre-established database of cooling medium thermodynamic properties or empirical formulas. For example, a two-dimensional lookup table can be constructed, where the rows and columns correspond to discrete temperature and pressure ranges, respectively. The table stores physical property parameters such as specific heat capacity and density of the cooling medium under these temperature and pressure combinations. After acquiring real-time temperature and pressure data, the system can perform interpolation or direct lookup in this lookup table to obtain the precise state parameters of the current cooling medium.

[0138] A metal rod processing control system, combined with Figure 10 As shown, the metal bar processing control system 1 includes:

[0139] The net heat flow value determination module 11 is used to acquire the temperature difference data and flow rate data of the cooling medium when it flows through the drawing die, and to determine the net heat flow value corresponding to the real-time thermal state of the drawing die based on the temperature difference data and flow rate data.

[0140] The reference heat flux calibration module 12 is used to calibrate the reference heat flux value based on the target processing state;

[0141] The drawing speed control module 13 is used to calculate the deviation between the net heat flow value and the reference heat flow value, and adjust the drawing speed according to the deviation so that the net heat flow value approaches the reference heat flow value, thereby controlling the metal bar processing process.

[0142] The net heat flow determination module is a functional unit used to monitor and calculate the thermal state of the drawing die in real time. It can be composed of a temperature sensor, a flow sensor, and a data processing unit. Its purpose is to accurately obtain the actual heat load of the die during processing. The reference heat flow calibration module is a functional unit used to establish a reference standard for the thermal state of the die based on preset ideal processing conditions. It can be composed of a data storage device and a calibration logic processing unit. Its purpose is to provide a stable target value for subsequent control. The drawing speed control module is a functional unit used to dynamically adjust the drawing process parameters based on the difference between the actual thermal state of the die and the reference standard. It can be composed of a deviation calculator and a speed regulator. Its purpose is to maintain the stability of the thermal state of the die by adjusting the drawing speed.

[0143] This application's solution achieves closed-loop control of the metal bar processing process by introducing a modular control system. Specifically, the net heat flux determination module first acquires real-time temperature difference and flow rate data of the cooling medium flowing through the drawing die, and calculates the current net heat flux value of the drawing die based on this data, reflecting the real-time thermal state of the die. This step overcomes the limitations of traditional local controllers that cannot sense the external environment and the state of related systems, providing basic data for subsequent precise control. Subsequently, the reference heat flux calibration module calibrates an ideal reference heat flux value based on a preset target processing state. This reference value represents the thermal equilibrium state that the die should have under the desired processing quality. Finally, the drawing speed control module receives the net heat flux value and the reference heat flux value, and calculates the deviation between the two. Based on this deviation, the drawing speed control module dynamically adjusts the drawing speed so that the net heat flux value of the die gradually approaches the calibrated reference heat flux value. In this way, the system can respond in real-time to changes in heat generation and dissipation conditions during processing, such as adjustments to the drawing speed or fluctuations in the efficiency of the cooling system, thereby maintaining the thermal state of the die within a stable range. This systematic design enables the various functional modules to work closely together in the processing, thereby effectively addressing the temperature fluctuations of the mold caused by both internal heat generation and external heat dissipation, thus suppressing irregular fluctuations in the diameter of the finished product and stabilizing it within the micron-level tolerance range.

[0144] In some preferred embodiments, the metal bar processing control system can be specifically implemented as follows: The net heat flux determination module may include two temperature sensors and one flow sensor installed at the inlet and outlet of the cooling circuit of the drawing die. These sensors transmit the collected temperature difference data and flow data to an embedded controller. The embedded controller runs a heat flux calculation algorithm, which can calculate the net heat flux of the die in real time based on the physical properties of the cooling medium, such as its specific heat capacity and density. The reference heat flux calibration module can be a standalone software program running on an industrial PC or PLC. When the operator inputs a "calibration command" through the human-machine interface and confirms that the current processing state is the target processing state, the program reads the net heat flux data output by the net heat flux determination module over a period of time and combines it with product size measurement data to determine whether the processing is stable and whether the product size is within the target tolerance range. Once the stability condition is met, the program determines and stores the current net heat flux value as the reference heat flux value. The drawing speed control module can be a software module based on a PID control algorithm, also running on an industrial PC or PLC. It continuously receives the real-time net heat flux value output by the net heat flux value determination module and the reference heat flux value provided by the reference heat flux calibration module, and calculates the error between the two. Then, based on preset control parameters (such as proportional gain, integral time, etc.), it generates an adjustment amount for the drawing speed. This adjustment amount is sent to the frequency converter or servo drive of the drawing machine, thereby adjusting the speed of the drawing motor, causing a corresponding change in the drawing speed, and ultimately causing the net heat flux value of the die to fall back or rise to near the reference heat flux value, thus achieving dynamic control of the processing.

[0145] Through the above technical solution, this application provides a metal bar processing control system. This system can sense the thermal state of the drawing die in real time and dynamically adjust the drawing speed according to the deviation from the target processing state. This enables the system to effectively cope with die temperature fluctuations caused by changes in internal heat generation and external environmental heat dissipation conditions, thereby suppressing irregular fluctuations in the finished product diameter and stabilizing it within the micron-level tolerance range. This system solves the problem that local controllers cannot obtain external environmental information and related system states, achieving precise control of the metal bar processing process.

[0146] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method of controlling a metal bar processing operation, characterized by, include: Acquire the temperature difference data and flow rate data of the cooling medium as it flows through the drawing die, and determine the net heat flow value corresponding to the real-time thermal state of the drawing die based on the temperature difference data and flow rate data. Based on the target processing state, the reference heat flux value is calibrated; The deviation between the net heat flux value and the reference heat flux value is calculated, and the drawing speed is adjusted according to the deviation to make the net heat flux value approach the reference heat flux value, so as to control the metal bar processing process.

2. A method of controlling a metal rod processing operation according to claim 1, wherein, The step of calibrating the reference heat flux value based on the target processing state includes: Receive calibration instructions; After receiving the calibration command, acquire the product size measurement data and net heat flow value data corresponding to the target processing state; Based on the product size measurement data, it is determined whether the product size is within the target tolerance range corresponding to the target processing state within a first preset time period, and the product size judgment result is obtained. Based on the net heat flow value data, it is determined whether the rate of change of the net heat flow value data within the second preset time period is lower than the stable threshold, and the net heat flow value judgment result is obtained. When the product size determination result is yes and the net heat flow value determination result is yes, the current net heat flow value data is determined as the baseline heat flow value.

3. A method of controlling a metal rod processing operation according to claim 2, wherein, The step of determining whether the rate of change of the net heat flux value data within a second preset time period is lower than a stable threshold, based on the net heat flux value data, and obtaining the net heat flux value determination result includes: Obtain the processing task identifier of the current processing task; Based on the processing task identifier, a stable threshold matching the processing task identifier is determined from the preset correspondence between stable thresholds and processing task identifiers; Within the second preset time period, the rate of change of the net heat flow value is calculated, and it is determined whether the rate of change of the net heat flow value is lower than the matched stability threshold, so as to obtain the net heat flow value judgment result.

4. A method of controlling a metal rod processing operation according to claim 1 wherein, The steps of calculating the deviation between the net heat flux value and the reference heat flux value, and adjusting the drawing speed according to the deviation to make the net heat flux value approach the reference heat flux value, for controlling the metal bar processing process, include: Obtain the drawing speed of the current processing step; Based on the drawing speed, control parameters matching the drawing speed are determined from the preset correspondence between the drawing speed range and the control parameters; The deviation between the net heat flux value and the reference heat flux value is processed using the control parameters to generate an adjustment amount for the drawing speed. The drawing speed is then adjusted according to the adjustment amount to make the net heat flux value approach the reference heat flux value, thereby controlling the metal bar processing process.

5. A method of controlling a metal rod processing operation according to claim 4, wherein, The step of determining the control parameters matching the drawing speed from the preset correspondence between the drawing speed range and the control parameters, based on the drawing speed, includes: Obtain the processing task identifier of the current processing task; Based on the processing task identifier, select the correspondence that matches the processing task identifier from a number of preset correspondences between drawing speed ranges and control parameters as the target correspondence; Based on the current drawing speed, control parameters are determined in the target correspondence.

6. A method of controlling a metal rod processing operation according to claim 5, wherein, The step of processing the deviation between the net heat flux value and the reference heat flux value using the control parameters to generate the adjustment amount of the drawing speed includes: A proportional adjustment component is generated based on the deviation between the net heat flux value and the reference heat flux value; An integral adjustment component is generated based on the time integral of the deviation between the net heat flux value and the reference heat flux value; The proportional adjustment component and the integral adjustment component are weighted using the control parameters to obtain a weighted component. The weighted components are combined to generate the adjustment amount for the drawing speed.

7. A method of controlling a metal rod processing operation according to claim 2 wherein, The step of determining whether the product size is within the target tolerance range corresponding to the target processing state within a first preset time period based on the product size measurement data, and obtaining the product size determination result, includes: Within a first preset time period, the product size measurement data are statistically processed to obtain central statistical values ​​and discrete statistical values; Determine whether the central statistical value and the discrete statistical value meet the preset statistical conditions to obtain the product size determination result.

8. The method for controlling the processing of metal rods according to claim 1, characterized in that, The step of determining the net heat flux value corresponding to the real-time thermal state of the drawing die based on the temperature difference data and flow rate data includes: Obtain the state parameters corresponding to the current physical state of the cooling medium; Based on the state parameters, physical characteristic parameters that match the state parameters are determined from the preset correspondence between physical characteristic parameters and state parameters; The net heat flux value is determined based on the temperature difference data, the flow rate data, and the physical characteristic parameters.

9. A method for controlling the processing of metal rods according to claim 8, characterized in that, The step of obtaining the state parameters corresponding to the current physical state of the cooling medium includes: Obtain the first state parameter corresponding to the first physical quantity of the cooling medium; Obtain the second state parameter corresponding to the second physical quantity of the cooling medium; The state parameters are determined based on the first state parameter and the second state parameter.

10. A metal bar processing control system for executing metal bar processing process control, characterized in that, include: The net heat flux determination module is used to acquire temperature difference data and flow rate data of the cooling medium when it flows through the drawing die, and to determine the net heat flux value corresponding to the real-time thermal state of the drawing die based on the temperature difference data and flow rate data. The reference heat flux calibration module is used to calibrate the reference heat flux value based on the target processing state; The drawing speed control module is used to calculate the deviation between the net heat flow value and the reference heat flow value, and adjust the drawing speed according to the deviation so that the net heat flow value approaches the reference heat flow value, thereby controlling the metal bar processing process.

Images