Electrolytic machine tool electrolyte monitoring device and method

Abstract

The invention relates to the technical field of industrial liquid online monitoring, and discloses an electrolytic machine tool electrolyte monitoring device and method, and the device comprises a housing, a PLC assembly and an upper computer connected with the housing, a circulating pipeline, and a sensor array integrated in the pipeline and a water tank. The sensor array covers a Cr6 sensor, a flow sensor, a conductivity meter sensor, an RH probe and a plurality of PH probes, and a protective shell is arranged outside the key sensor. A plurality of sensors are integrated in a unified circulating system, liquid parameter signals acquired by the sensors are gathered and processed in real time by the PLC component, analysis results are transmitted to the upper computer for centralized display and monitoring, and state early warning is performed by the three-color warning lamp. According to the invention, the defects of low automation degree, non-systematic data, feedback lagging and easy damage of the sensor in the existing monitoring technology are overcome, and comprehensive, real-time and intelligent monitoring of the key parameters of the liquid is realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of industrial liquid online monitoring, in particular to an electrolytic machine tool electrolyte monitoring device and method. BACKGROUND

[0002] In modern industrial production, especially in the chemical industry, electroplating, water treatment and precision manufacturing industries, the physical and chemical parameters of process liquids, such as pH value, conductivity, specific ion concentration (such as hexavalent chromium), flow rate and temperature, play a crucial role in product quality, production efficiency and even environmental protection. In order to ensure the stability of the production process and the qualification rate of the final product, these key parameters must be accurately and real-time monitored.

[0003] However, the existing technical solutions often appear to be inadequate in response to this demand. The current monitoring means are generally not highly automated and intelligent, and many times still rely on manual sampling and offline analysis, which not only consumes a lot of manpower, but more seriously, its feedback is lagging, which makes the system unable to quickly adjust when the liquid parameters fluctuate abnormally, easily causing the entire batch of products to be scrapped or production accidents. Even some scenes use automated monitoring equipment, but these devices are often single-function and independent of each other. For example, the pH monitoring system and the flow monitoring system come from different manufacturers, and their data and control logic cannot be integrated into a unified platform, forming an information island, making it difficult for managers to obtain a comprehensive process view and to achieve intelligent control of multiple parameters in coordination. In addition, the industrial site environment is usually harsh, and the precision components such as sensors deployed on the production line are easily damaged by impact, corrosion or dust pollution, resulting in inaccurate measurement data, which not only affects the control effect, but also increases the maintenance cost and failure risk of the equipment. Therefore, the existing technology has obvious shortcomings in real-time monitoring, system integration and reliability of operation, and it is difficult to meet the stringent requirements of modern industry for efficient, accurate and stable production. SUMMARY

[0004] In view of the shortcomings of the prior art, the present application provides an electrolytic machine tool electrolyte monitoring device and method, which solves the problems of low automation of existing monitoring means, reliance on manual sampling analysis leading to feedback lag, and inability to achieve real-time online monitoring. At the same time, the present application also solves the problem that it is difficult to comprehensively and integrally manage and cooperatively control liquid parameters due to the independence of each monitoring function and the dispersion of data.

[0005] To achieve the above purpose, the present application realizes the following technical scheme: an electrolytic machine tool electrolyte monitoring device and method, comprising a shell, an electrolyte circulating assembly is arranged inside the shell, and an electrolyte monitoring assembly is arranged outside the shell;

[0006] The electrolyte monitoring assembly comprises a flow sensor, an RH meter, a PH meter 1, a conductivity meter, a Cr6 sensor and a PH meter 2, the Cr6 sensor, the flow sensor, the RH meter, the PH meter 1 and the PH meter 2 are arranged on the side of the shell, the conductivity meter is arranged outside the end of the shell, the output end of the RH meter is fixedly connected with an RH probe, the output ends of the PH meter 1 and the PH meter 2 are fixedly connected with two PH probes 1 and 2 respectively, and the output end of the conductivity meter is fixedly connected with a plurality of conductivity meter sensors.

[0007] Preferably, the electrolyte circulating assembly comprises a water tank, the water tank is fixedly connected to the inner side of the shell, a water pump is fixedly connected to the end side of the water tank, the output end of the water pump is fixedly connected with a circulating pipeline, the circulating pipeline is arranged between the shell and the water tank, and the other end of the circulating pipeline is fixedly connected to the end inner side of the water tank.

[0008] Preferably, a connecting plate is fixedly connected to the side of the shell, a PLC assembly is fixedly connected to the side of the connecting plate, an upper computer is arranged on the side of the PLC assembly, two three-color warning lights are fixedly connected to the end of the connecting plate away from the PLC assembly, a plurality of bases are fixedly connected to the bottom of the shell, and the bottom of the connecting plate is also fixedly connected with a base.

[0009] Preferably, a plurality of conductivity meter sensors are arranged on the end inner side of the water tank, one end of the Cr6 sensor and the flow sensor monitored is arranged in the inside of the circulating pipeline, the RH probe, the two PH probes 1 and the two PH probes 2 are arranged on the inside of the circulating pipeline, an RH sensor is arranged in the inside of the RH probe, a protective shell is fixedly connected to the side of the shell, and the protective shell is arranged outside the Cr6 sensor.

[0010] A method for preparing the electrolyte monitoring device of the electrolytic machine of any one of claims 1-4, comprising the following steps:

[0011] S1, using the electrolyte circulating assembly to make the electrolyte circulate between the water tank and the circulating pipeline;

[0012] S2, using the conductivity meter sensor, the PH probe 1, the RH probe, the flow sensor, the Cr6 sensor and the PH probe 2 to collect the real-time data of the conductivity, the PH value, the RH value, the flow and the Cr6 content of the electrolyte in real time;

[0013] S3, transmit the real-time data of the conductivity, PH value, RH value, flow and Cr6 content of the electrolyte collected in real time to the upper computer through the PLC assembly;

[0014] S4, the upper computer compares the received real-time data with the preset parameter range for judgment;

[0015] S5, when the upper computer judges that any of the real-time data exceeds the parameter range, the three-color warning light is triggered to alarm.

[0016] Preferably, in the S2 step, specifically comprising:

[0017] The first PH value and the second PH value are transmitted to the upper computer.

[0018] The first PH value and the second PH value are transmitted to the upper computer.

[0019] The upper computer compares the first PH value and the second PH value in real time, and when the difference between the two values exceeds the preset tolerance, it is judged that the PH monitoring data is abnormal and the three-color warning light is triggered to alarm.

[0020] Preferably, in the S2 step, the plurality of conductivity meter sensors monitor the overall reference conductivity of the electrolyte in the water tank.

[0021] The PH probe 1, the RH probe, the flow sensor, the Cr6 sensor and the PH probe 2 monitor the real-time dynamic parameters of the electrolyte in the circulating pipeline.

[0022] Preferably, in the S3 step, the conductivity meter, the PH meter 1, the RH meter and the PH meter 2 convert the collected data into analog signals, and the PLC assembly receives the analog signals and converts them into digital signals before transmitting them to the upper computer.

[0023] Preferably, in the S5 step, the upper computer controls the three-color warning light to display different colored lights according to the deviation of the real-time data from the preset parameter range, and simultaneously outputs a text prompt on the display interface of the upper computer.

[0024] Preferably, when the upper computer judges that the PH monitoring data is abnormal, the upper computer suspends the alarm judgment based on the PH value and preferentially triggers a specific alarm indicating a PH sensor failure.

[0025] The present application provides an electrolytic machine tool electrolyte monitoring device and method. It has the following advantages:

[0026] 1、The present application is provided by setting by PH instrument 17 and PH probe 112, PH instrument 219 and PH probe 220 two independent PH monitoring channels, so that the host computer 8 can compare the first PH value and the second PH value collected in real time.When the difference between the two values exceeds the preset tolerance, the system can judge that the PH monitoring data is abnormal, and preferentially trigger the specific alarm indicating sensor failure. This design can effectively identify and isolate the drift or failure of a single sensor, prevent the system from making incorrect alarms or judgments based on incorrect PH data, and ensure the stability and reliability of the entire monitoring system.

[0027] 2、The present application integrates conductivity instrument sensor 14, PH probe 112, RH probe 11, flow sensor 5, Cr6 sensor 17 and PH probe 220, which can monitor multiple core parameters affecting the electrolytic machining process. Through the automatic data link composed of PLC component 18 and host computer 8, the whole process automation from data acquisition, transmission to comparison and judgment is realized. This overcomes the hysteresis and incompleteness of traditional manual and offline detection, can timely find the small changes of electrolyte composition, and immediately remind the operator through the three-color warning light 9, ensures that the electrolyte quality is always maintained within the best process range, and ensures the precision and consistency of electrolytic machining.

[0028] 3、The host computer 8 of the present application can not only alarm when the parameter is out of limit, but also control the three-color warning light 9 to display different colored lights according to the deviation degree of real-time data from the preset parameter range, and assist with text prompts, so that the operator can intuitively understand the emergency degree of the problem. More importantly, the system can distinguish whether the process parameter is abnormal or the sensor itself is faulty, and trigger different specific alarms. This intelligent alarm mechanism provides more accurate and more instructive fault information for the operator, helping him to quickly locate the problem source and take the correct response measures. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 It is a perspective view of the present application;

[0030] Figure 2 It is a schematic diagram of the conductivity instrument of the present application;

[0031] Figure 3 It is a schematic diagram of the PH instrument 2 of the present application;

[0032] Figure 4 It is a schematic diagram of the circulating pipeline of the present application;

[0033] Figure 5 It is a schematic diagram of the host computer of the present application;

[0034] Figure 6 It is a schematic diagram of the Cr6 sensor of the present application;

[0035] Figure 7 is a schematic diagram of the flow sensor of the present application;

[0036] Figure 8 is a schematic diagram of the RH probe of the present application;

[0037] Figure 9 is a schematic diagram of the PH meter 1 of the present application;

[0038] Figure 10 is a schematic diagram of the PH probe 2 of the present application;

[0039] Figure 11 is a schematic diagram of the conductivity meter sensor of the present application;

[0040] Figure 12 is a schematic diagram of the water pump of the present application;

[0041] Figure 13 is a schematic diagram of the electrolyte monitoring device of the electrolytic machine tool of the present application;

[0042] Figure 14 is a schematic diagram of the electrical element wiring of the present application.

[0043] Wherein, 1, shell; 2, base; 3, connecting plate; 4, protective shell; 5, flow sensor; 6, RH meter; 7, PH meter 1; 8, upper computer; 9, three-color warning light; 10, conductivity meter; 11, RH probe; 12, PH probe 1; 13, circulating pipeline; 14, conductivity meter sensor; 15, water pump; 16, water tank; 17, Cr6 sensor; 18, PLC assembly; 19, PH meter 2; 20, PH probe 2. DETAILED DESCRIPTION

[0044] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the specification of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0045] Please refer to the drawings in the specification of the present application Figure 1 - the drawings in the specification of the present application Figure 9 The electrolyte monitoring device and method of the electrolytic machine tool provided by the embodiments of the present application, the shell 1, the electrolyte circulating assembly is arranged inside the shell 1, and the electrolyte monitoring assembly is arranged outside the shell 1.

[0046] The electrolyte monitoring assembly includes a flow sensor 5, an RH meter 6, a pH meter 17, a conductivity meter 10, a Cr6 sensor 17, and a pH meter 219. The Cr6 sensor 17, flow sensor 5, RH meter 6, pH meter 17, and pH meter 219 are all located on the side of the housing 1. The conductivity meter 10 is located on the outer side of the end of the housing 1. An RH probe 11 is fixedly connected to the output end of the RH meter 6. Two pH probes 112 and 220 are fixedly connected to the output ends of the pH meter 17 and pH meter 219, respectively. Multiple conductivity meter sensors 14 are fixedly connected to the output end of the conductivity meter 10.

[0047] Specifically, flow sensor 5 is used to monitor the circulating flow rate of the electrolyte in the electrolysis machine tool in real time to ensure that the electrolyte is supplied at a stable rate. RH meter 6, connected to RH probe 11 at its output, is used to detect the redox potential (ORP) of the electrolyte. pH meters 17 and 219, connected to their respective pH probes 112 and 220, are used to monitor the pH value at different locations in the electrolyte circulation loop, thereby enabling precise control and adjustment of the electrolyte's chemical properties. Conductivity meter 10, connected to multiple conductivity sensors 14 at its output, is used to measure the conductivity of the electrolyte; conductivity is a key parameter reflecting the ion concentration and conductivity of the electrolyte. Cr6 sensor 17 is specifically used to detect the concentration of hexavalent chromium (Cr6+) ions in the electrolyte.

[0048] Please see the appendix Figure 3 Appendix Figure 4 and attached Figure 10 The electrolyte circulation assembly includes a water tank 16, which is fixedly connected to the inside of the outer shell 1. A water pump 15 is fixedly connected to the side of the end of the water tank 16. A circulation pipe 13 is fixedly connected to the output end of the water pump 15. The circulation pipe 13 is disposed between the outer shell 1 and the water tank 16. The other end of the circulation pipe 13 is fixedly connected to the inside of the end of the water tank 16.

[0049] Specifically, the water tank 16 is used to store the electrolyte and provide liquid for the entire circulation system; the water pump 15 is used to draw the electrolyte from the inside of the water tank 16 into the circulation pipe 13 to provide power for the circulation of the electrolyte; the circulation pipe 13 is used to provide a flow channel for the electrolyte drawn out by the water pump 15, so that it eventually flows back into the water tank 16, forming a complete circulation loop, thereby achieving cooling or stirring of the electrolyte and maintaining its stable performance.

[0050] Please see the appendix Figure 1 - Appendix Figure 4The shell 1 side is fixedly connected with a connecting plate 3, the connecting plate 3 side is fixedly connected with a PLC assembly 18, the PLC assembly 18 side is provided with an upper computer 8, the connecting plate 3 away from the PLC assembly 18 one end is fixedly connected with two three-color warning lights 9, the shell 1 bottom is fixedly connected with a plurality of bases 2, the connecting plate 3 bottom is also fixedly connected with the base 2. A plurality of conductivity instrument sensors 14 are arranged in the inside of the end of the water tank 16, and one end of the Cr6 sensor 17 and the flow sensor 5 monitored is arranged in the inside of the circulating pipeline 13, and the RH probe 11, two PH probes 112 and two PH probes 220 are arranged in the inside of the circulating pipeline 13, and the RH probe 11 is provided with an RH sensor, and the shell 1 side is fixedly connected with a protective shell 4, and the protective shell 4 is arranged outside the Cr6 sensor 17.

[0051] Specifically, the PLC assembly 18 serves as the central processing unit, responsible for receiving signals collected by all sensors and automatically controlling the entire system according to pre-set logic programs. The upper computer 8 provides an interface for human-computer interaction, displaying real-time data transmitted from the PLC assembly 18 and allowing operators to monitor and issue commands to the device. The three-color warning light 9 indicates the running state of the device by emitting different colors of light, such as normal, warning or failure. The base 2 provides structural support for the entire device, ensuring its stable placement. The conductivity instrument sensor 14 is used to measure the conductivity of the liquid in the water tank 16, reflecting the total solid content dissolved in the liquid. The Cr6 sensor 17 and the flow sensor 5 are used to monitor the concentration of hexavalent chromium and the flow rate of the liquid in the circulating pipeline 13 in real time. The RH probe 11 and its internal RH sensor, two PH probes 112 and two PH probes 220 are used to monitor the chemical properties of the liquid in the circulating pipeline 13, measuring the oxidation-reduction potential RH and the pH of the liquid, respectively. Setting multiple probes can accurately monitor the liquid at different positions. The protective shell 4 provides physical protection for the external Cr6 sensor 17, preventing it from being damaged by accidental impact or environmental factors.

[0052] Please refer to the attached Figure 1 - attached Figure 12 First, start the water pump 15 in the electrolyte circulation assembly, which is step S1. The water pump 15 drives the electrolyte to flow out of the water tank 16, into the circulating pipeline 13, and finally back to the water tank 16, establishing a continuous circulating flow state.

[0053] In the electrolyte circulation process, the electrolyte monitoring assembly begins to collect data in real time, which is step S2. A plurality of conductivity meter sensors 14 are arranged inside the water tank 16 for monitoring the overall reference conductivity of the electrolyte in the water tank 16. The PH probe 112, the PH probe 220, the RH probe 11, the flow sensor 5 and the Cr6 sensor 17 are all arranged inside the circulation pipeline 13 for monitoring the real-time dynamic parameters of the electrolyte flowing through the pipeline. The PH probe 112 and the PH probe 220 respectively collect and obtain the first PH value and the second PH value in real time.

[0054] In step S3, the real-time data of the conductivity, PH value, RH value, flow rate and Cr6 content of the electrolyte collected in real time are transmitted to the upper computer 8 through the PLC assembly 18. Specifically, the conductivity meter 10, the PH meter 17, the RH meter 6 and the PH meter 219 respectively receive the signals of the corresponding sensors or probes, and convert the signals into analog signals. The analog input module of the PLC assembly 18 receives all the analog signals, and the PLC assembly 18 converts the received analog signals into digital signals and transmits the digital signals to the upper computer 8 through an industrial communication protocol.

[0055] In step S4, the upper computer 8 analyzes and judges the received real-time data.

[0056] For conductivity, RH value, flow rate and Cr6 content, the upper computer 8 compares each real-time data with the corresponding preset parameter range, and when the following conditions are met, it is judged that the parameter is out of limit:

[0057] ;

[0058] Wherein: is the real-time measurement value of conductivity, RH value, flow rate or Cr6 content; is the preset lower limit value of the corresponding parameter; is the preset upper limit value of the corresponding parameter.

[0059] For the PH value, the upper computer 8 first performs consistency check on the received first PH value and second PH value, and when the following conditions are met, it is judged that the PH monitoring data is abnormal:

[0060] ;

[0061] Wherein: is the first PH value measured by the first channel composed of the PH probe 112 and the PH meter 17; is the second PH value measured by the second channel composed of the PH probe 220 and the PH meter 219; is the preset PH value allowable difference according to the process precision requirement, which is a fixed positive number.

[0062] In step S5, when the host computer 8 makes a judgment of parameter overrun or data abnormality in step S4, an alarm is triggered. When it is judged that the conductivity, RH value, flow rate, or Cr6 content parameter is overrun, the host computer 8 controls the three-color warning light 9 to be lit. The host computer 8 can control the three-color warning light 9 to display different colors according to the degree to which the real-time data deviates from the preset parameter range. At the same time, the host computer 8 outputs specific text prompts on the display interface, including the parameter name and specific value of the abnormality.

[0063] When it is judged that the PH monitoring data is abnormal, the host computer 8 executes a specific alarm process. In this process, the system suspends the judgment of whether the first PH value or the second PH value itself is overrun, and instead triggers a specific alarm indicating a PH sensor or probe failure. The specific alarm can display a specific color or flashing mode through the three-color warning light 9, and be accompanied by specific text prompts.

[0064] The electrolytic machine electrolyte monitoring method of the present application utilizes the technical solution of deploying sensors at different positions to collect data of different properties. This solution corresponds the monitoring function of the sensors to their physical positions in the electrolyte system to obtain parameters representing different state dimensions of the electrolyte.

[0065] Specifically, the multiple conductivity meter sensors 14 are arranged inside the water tank 16. The electrolyte at this position is subjected to circulation and mixing, and its physicochemical parameters represent the overall average state of the entire electrolyte system. Therefore, the conductivity data collected by the conductivity meter sensors 14 is defined as the overall reference conductivity of the electrolyte. This overall reference conductivity is mainly used to represent long-term and slow change trends caused by factors such as water evaporation and overall consumption of electrolyte components.

[0066] At the same time, the PH probe 112, the PH probe 220, the RH probe 11, the flow rate sensor 5, and the Cr6 sensor 17 are all arranged inside the circulation pipeline 13. The electrolyte at this position is directly involved in the immediate circulation process of electrolytic processing, and its parameter state directly reflects the instantaneous influence of electrolytic processing actions on the electrolyte flowing through. Therefore, the data collected by these sensors and probes is defined as the real-time dynamic parameters of the electrolyte.

[0067] The host computer 8 is configured to simultaneously receive and process the overall reference conductivity and the real-time dynamic parameters. By analyzing and comparing these two types of data of different properties, the system can distinguish between overall state degradation of the electrolyte and local instantaneous changes caused by the processing process, providing a multi-dimensional data basis for subsequent alarm judgments.

[0068] The electrolyte monitoring method for electrolytic machine tools of the present invention includes a dual-channel redundant monitoring and fault diagnosis process to improve the reliability of pH value monitoring. This process utilizes two independent pH monitoring hardware channels and compares data to determine the status of the monitoring system itself.

[0069] The device includes two parallel pH monitoring channels. The first channel consists of a pH meter 17 and its connected pH probe 112; the second channel consists of a pH meter 219 and its connected pH probe 220. During monitoring, these two channels simultaneously measure the pH value of the electrolyte in the circulation pipe 13, obtaining a first pH value (…). ) and second pH value ( These two data sets were transmitted independently to the host computer 8.

[0070] The host computer 8 is configured to execute a data consistency verification algorithm. This algorithm compares the first and second pH values ​​received in real time, and determines that the pH monitoring data is abnormal when the following conditions are met:

[0071] ;

[0072] in: The first pH value is measured by the first channel, which is composed of pH probe 112 and pH meter 17. The second pH value is measured by the second channel, which consists of pH probe 220 and pH meter 219. It is a preset allowable difference in pH value based on the process precision requirements, and is a fixed positive number.

[0073] When the host computer 8 determines that an abnormal pH monitoring data has occurred, its alarm logic is configured to execute a specific procedure. In this procedure, the host computer 8 suspends the execution of regular operations based on a single pH value (…). or Alarm judgment for whether the preset process parameters are exceeded.

[0074] Instead, the host computer 8 prioritizes triggering a specific alarm to indicate a malfunction in the pH monitoring channel. This specific alarm is displayed by a preset fault color or flashing pattern on a tri-color warning light 9, and can output clear text information on the host computer 8's display interface, indicating that the pH monitoring system has data inconsistency. In this way, the system can distinguish between measurement data deviations caused by sensor or probe failure and parameter drift caused by changes in the actual chemical state of the electrolyte, thereby avoiding erroneous process alarms caused by equipment failure.

[0075] The data link and signal processing flow of the monitoring method of the present application defines a complete path from the original signal generated by the sensor to the digital data received by the host computer. This path ensures that the chemical or physical quantity in the physical world can be accurately converted into digital information that can be processed by the computer.

[0076] The conductivity meter sensor 14, the PH probe 112, the PH probe 220, the flow sensor 5, the Cr6 sensor 17 and the RH probe 11 change the physical or chemical properties of their internal elements when in contact with the electrolyte, generating an original electrical signal corresponding to the measured quantity. This original electrical signal is transmitted to the conductivity meter 10, the PH meter 17, the PH meter 219 and the RH meter 6, respectively, to which it is connected. The function of the meter is to linearly convert the input original electrical signal into a standardized analog signal, such as a 4-20 mA DC current signal or a 0-10 V DC voltage signal.

[0077] All the standardized analog signals output by the meters are connected to the analog input channels of the PLC assembly 18 through shielded cables. The PLC assembly 18 performs analog-to-digital conversion on the signal of each analog input channel, converting the continuous analog signal into a discrete digital value. The conversion process follows a linear mapping relationship, which can be represented as:

[0078] ;

[0079] Where: is the digital value output after analog-to-digital conversion; is the real-time value of the analog signal received by the PLC assembly 18, such as current or voltage; and are the lower and upper limits of the range of the analog signal, such as 4 mA and 20 mA; and are the lower and upper limits of the range of the internal digital value of the PLC assembly 18, such as 0 and 27648.

[0080] The PLC assembly 18 packs all the digital values of the channels obtained after internal processing into a data frame. Subsequently, the PLC assembly 18 transmits the data frame to the host computer 8 via a physical communication link through a pre-set industrial communication protocol. The host computer 8 receives and parses the data frame, thereby obtaining the accurate digital quantity corresponding to the measurement value of each sensor, for subsequent comparison, judgment and alarm processing. The alarm principle of the monitoring method of the present application is based on the classification judgment and hierarchical response of abnormal events. The alarm logic of the host computer 8 is configured to first distinguish the category of the alarm event, and then process the alarm of a specific category according to its deviation degree.

[0081]

[0082] ​The categories of alarm events are divided into two categories: one is the monitoring system itself failure, and the other is the electrolyte process parameter out of limit. The host computer 8 judges the monitoring system itself failure by executing the aforementioned PH value double-channel redundant monitoring process. When the absolute value of the difference between the first PH value and the second PH value exceeds the preset allowable difference, the system determines that the monitoring system itself failure occurs, and executes the specific alarm process for this category of failure. For all other parameter comparisons in addition to the PH value consistency check, when the real-time data exceeds the preset process parameter range, the system determines that the electrolyte process parameter out of limit occurs.

[0083] For the category of electrolyte process parameter out of limit, the host computer 8 executes hierarchical alarm. This hierarchy is achieved by setting two levels of thresholds for each monitored process parameter (such as conductivity, RH value, etc.). The first level is the pre-warning threshold, and the second level is the alarm threshold.

[0084] Specifically, for the real-time measurement value of any parameter , the hierarchical judgment condition is as follows:

[0085] When the real-time measurement value exceeds the alarm threshold range, trigger the second-level alarm :

[0086] ;

[0087] When the real-time measurement value does not exceed the alarm threshold range, but exceeds the pre-warning threshold range, trigger the first-level alarm:

[0088] ;

[0089] Wherein: is the real-time measurement value of a certain process parameter; is the pre-warning threshold range set for the parameter; is the alarm threshold range set for the parameter, and satisfies and .

[0090] The host computer 8 maps the category and level of the alarm to different output signals. When the first-level alarm is triggered, the host computer 8 controls the three-color warning light 9 to display the first preset color (such as yellow). When the second-level alarm is triggered, the host computer 8 controls the three-color warning light 9 to display the second preset color (such as red). When it is judged that the monitoring system itself failure (such as PH monitoring data abnormality) occurs, the host computer 8 controls the three-color warning light 9 to display the third preset color or a specific flashing mode. In all cases, the display interface of the host computer 8 synchronously outputs a text prompt, which includes the parameter name, real-time value, category and level of the triggered alarm.

Claims

1. A device for monitoring electrolyte in an electrolytic machine tool, characterized in that, include: The outer casing (1) is provided with an electrolyte circulation assembly inside the outer casing (1) and an electrolyte monitoring assembly is provided on the outer side of the outer casing (1); The electrolyte monitoring assembly includes a flow sensor (5), an RH meter (6), a pH meter 1 (7), a conductivity meter (10), a Cr6 sensor (17), and a pH meter 2 (19). The Cr6 sensor (17), flow sensor (5), RH meter (6), pH meter 1 (7), and pH meter 2 (19) are all located on the side of the housing (1). The conductivity meter (10) is located on the outer side of the end of the housing (1). The output end of the RH meter (6) is fixedly connected to an RH probe (11). The output ends of the pH meter 1 (7) and pH meter 2 (19) are respectively fixedly connected to two pH probes 1 (12) and 2 (20). The output end of the conductivity meter (10) is fixedly connected to multiple conductivity meter sensors (14).

2. The electrolyte monitoring device for an electrolytic machine tool according to claim 1, characterized in that, The electrolyte circulation assembly includes a water tank (16), which is fixedly connected to the inner side of the outer shell (1). A water pump (15) is fixedly connected to the side of the end of the water tank (16). A circulation pipe (13) is fixedly connected to the output end of the water pump (15). The circulation pipe (13) is located between the outer shell (1) and the water tank (16). The other end of the circulation pipe (13) is fixedly connected to the inner side of the end of the water tank (16).

3. The electrolyte monitoring device for an electrolytic machine tool according to claim 1, characterized in that, A connecting plate (3) is fixedly connected to the side of the outer shell (1), a PLC assembly (18) is fixedly connected to the side of the connecting plate (3), a host computer (8) is provided on the side of the PLC assembly (18), two three-color warning lights (9) are fixedly connected to the end of the connecting plate (3) away from the PLC assembly (18), multiple bases (2) are fixedly connected to the bottom of the outer shell (1), and a base (2) is also fixedly connected to the bottom of the connecting plate (3).

4. The electrolyte monitoring device for an electrolytic machine tool according to claim 1, characterized in that, Multiple conductivity meter sensors (14) are located inside the end of the water tank (16). The Cr6 sensor (17) and the flow sensor (5) are located inside the circulation pipe (13). The RH probe (11), two pH probes 1 (12) and two pH probes 2 (20) are located inside the circulation pipe (13). The RH probe (11) is equipped with an RH sensor. A protective shell (4) is fixedly connected to the side of the outer shell (1). The protective shell (4) is located outside the Cr6 sensor (17).

5. A method for preparing the electrolyte monitoring device for an electrolytic machine tool according to any one of claims 1-4, characterized in that, Includes the following steps: S1. The electrolyte is circulated between the water tank (16) and the circulation pipe (13) using the electrolyte circulation assembly; S2. Real-time data of the conductivity, pH value, RH value, flow rate and Cr6 content of the electrolyte are collected using the conductivity meter sensor (14), the pH probe 1 (12), the RH probe (11), the flow sensor (5), the Cr6 sensor (17) and the pH probe 2 (20). S3. Real-time data of electrolyte conductivity, pH value, RH value, flow rate and Cr6 content are collected and transmitted to the host computer (8) through the PLC component (18). S4. The host computer (8) compares the received real-time data with the preset parameter range to make a judgment. S5. When the host computer (8) determines that any of the real-time data exceeds the parameter range, it triggers the three-color warning light (9) to issue an alarm.

6. The method for monitoring electrolyte in an electrolytic machine tool according to claim 5, characterized in that, Step S2 specifically includes: The first pH value and the second pH value are collected using two pH probes 1 (12) and two pH probes 2 (20), respectively; The first pH value and the second pH value are transmitted to the host computer (8); The host computer (8) compares the first pH value and the second pH value in real time. When the difference between the two values ​​exceeds the preset tolerance, it is determined that the pH monitoring data is abnormal and the three-color warning light (9) is triggered to alarm.

7. The method for monitoring electrolyte in an electrolytic machine tool according to claim 5, characterized in that, In step S2, the plurality of conductivity meter sensors (14) monitor the overall reference conductivity of the electrolyte in the water tank (16); The pH probe 1 (12), the RH probe (11), the flow sensor (5), the Cr6 sensor (17), and the pH probe 2 (20) monitor the real-time dynamic parameters of the electrolyte in the circulation pipeline (13).

8. The method for monitoring electrolyte in an electrolytic machine tool according to claim 5, characterized in that, In step S3, the conductivity meter (10), pH meter 1 (7), RH meter (6) and pH meter 2 (19) convert the collected data into analog signals. The PLC component (18) receives the analog signals and converts them into digital signals before transmitting them to the host computer (8).

9. The method for monitoring electrolyte in an electrolytic machine tool according to claim 5, characterized in that, In step S5, the host computer (8) controls the tri-color warning light (9) to display different colors of light according to the degree of deviation between the real-time data and the preset parameter range, and simultaneously outputs text prompts on the display interface of the host computer (8).

10. The method for monitoring electrolyte in an electrolytic machine tool according to claim 6, characterized in that, When the host computer (8) determines that the pH monitoring data is abnormal, the host computer (8) suspends the alarm judgment based on the pH value and prioritizes triggering a specific alarm indicating a pH sensor failure.

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