Automatic impregnation process and system for solid aluminum electrolytic capacitor

Abstract

The invention discloses an automatic impregnation process for a solid aluminum electrolytic capacitor, which comprises the following steps: a parameter presetting step: based on impregnation process requirements of different series of products, presetting and storing a plurality of parameter combinations in an impregnation machine control system, each parameter combination at least comprising a negative pressure value, an immersion time length and a pressure relief rate, the identification code is uniquely associated with one product series identification code; a production type selection step: inputting or selecting an identification code corresponding to a to-be-processed product series through an operation interface; and an automatic execution step: the control system automatically calls the corresponding parameter combination according to the selected identification code, and controls the impregnation machine to sequentially execute an automatic impregnation process including vacuumizing, injecting and maintaining impregnation liquid soaking, and stable pressure relief. The full-process automation and standardization of the impregnation process are realized, so that the problems of low efficiency, complicated operation and poor flexibility of the traditional process are solved, and finally, the purposes of improving the production efficiency, ensuring the quality consistency and reducing the operation threshold and the production cost are achieved.

Description

Technical Field

[0001] This invention relates to the field of aluminum electrolytic capacitor manufacturing technology, specifically to an automated impregnation process and system for solid aluminum electrolytic capacitors. Background Technology

[0002] In the production of solid aluminum electrolytic capacitors, impregnation is a crucial process. Its purpose is to thoroughly impregnate the conductive polymer precursor solution (impregnation liquid) into the pores between the etched anode and cathode foils. Traditional impregnation processes rely heavily on manual control based on operator experience. Specifically, for different series and specifications of capacitors, multiple core process parameters, such as negative pressure intensity, holding time, pressure release rate, and impregnation liquid level, need to be manually set and adjusted on the impregnation machine. This approach has significant drawbacks: First, each product changeover requires repeated, tedious parameter setting and verification, which is time-consuming and severely restricts production efficiency, making it difficult to adapt to the flexible production needs of multiple varieties and small batches. Second, manual operation is prone to parameter setting deviations or improper operation due to fatigue, negligence, or differences in experience. This uncertainty directly affects the uniformity and depth of impregnation liquid penetration, leading to large dispersion in product electrical performance parameters and unstable product yield. Furthermore, the complex parameter adjustments require highly skilled operators, resulting in high training costs. With industrial upgrading, the market demands increasingly higher requirements for capacitor quality consistency and production efficiency. The traditional immersion model, which relies on manual experience, has become a major bottleneck for the industry to improve quality and efficiency.

[0003] Therefore, there is an urgent need for an intelligent impregnation solution that can achieve precise and automated execution of process parameters and can quickly adapt to the production of different products. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the aforementioned background technology and provide an automated impregnation process and system for solid aluminum electrolytic capacitors. This invention aims to achieve full automation and standardization of the impregnation process through digital preset and one-click recall of process parameters, thereby solving the problems of low efficiency, reliance on manual labor for quality, cumbersome operation, and poor flexibility in traditional processes. Ultimately, it aims to improve production efficiency, ensure product quality consistency, and reduce operational barriers and production costs.

[0005] To achieve the above objectives, the present invention provides the following technical solution: In a first aspect, the present invention provides an automated impregnation process for solid aluminum electrolytic capacitors, comprising the following steps: Parameter preset steps: Based on the impregnation process requirements of different product series, multiple parameter combinations are preset and stored in the impregnation machine control system. Each parameter combination includes at least negative pressure value, impregnation time and pressure relief rate, and is uniquely associated with a product series identification code. Production selection steps: Enter or select the identification code corresponding to the product series to be processed through the operation interface; Automatic execution steps: The control system automatically calls the corresponding parameter combination according to the selected identification code, and controls the impregnation machine to sequentially execute the automatic impregnation process, including vacuuming, injecting and maintaining the impregnation liquid, and stable depressurization.

[0006] Furthermore, in the parameter preset step, the preset parameter combination also includes the impregnation liquid level parameter; in the automatic execution step, the control system replenishes the impregnation liquid in real time according to the feedback from the liquid level detection mechanism to maintain the preset liquid level.

[0007] Preferably, the automatic execution steps specifically include: S1. Control the sealing of the impregnation tank and evacuate the vacuum according to the preset negative pressure value; S2. Once the set negative pressure is reached, the impregnation solution is automatically injected to the preset level. The preset soaking time is maintained, with real-time replenishment based on the liquid level detection feedback during this period. S3. After soaking, release the pressure steadily according to the preset pressure release rate. The pressure release rate is configured to avoid sudden pressure changes that could damage the internal structure of the product. S4. After the pressure relief is completed, perform the final actions of impregnating liquid reflux and material lifting.

[0008] Furthermore, the process also includes a parameter adjustment step: adding, modifying, or deleting stored parameter combinations through the control system to adapt to the production needs of products with different specifications.

[0009] Furthermore, the impregnation process modes defined by the parameter combination include, but are not limited to, negative pressure impregnation mode or alternating positive and negative pressure impregnation mode.

[0010] In a second aspect, the present invention provides an automatic impregnation system for implementing the above-described automatic impregnation process, comprising: The main body of the impregnation machine includes an impregnation tank, a sealing cover, a vacuum pump, a liquid injection mechanism, a pressure relief valve, and a material rack for carrying materials; A parameter database is used to store combinations of impregnation process parameters that are uniquely associated with identification codes for different product series. The selection input module is used to receive the product series identification code input by the user. The control module is connected to the selection input module, parameter database and impregnation machine main body signal. It is used to call the corresponding parameter combination according to the identification code and drive the impregnation machine main body to automatically complete the impregnation operation based on the parameter combination.

[0011] Preferably, it also includes a liquid level detection mechanism for real-time monitoring of the liquid level in the impregnation tank; the control module controls the injection mechanism according to the feedback signal from the liquid level detection mechanism to maintain the preset liquid level.

[0012] Preferably, the sealing cover is provided with an automatic locking mechanism, which is controlled by the control module to lock and release.

[0013] Preferably, the selection input module is integrated on the operation panel of the immersion machine body, and the operation panel includes at least one of physical buttons, a touch screen, or a scanner.

[0014] Thirdly, the present invention provides a control system including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps of the automatic impregnation process for solid aluminum electrolytic capacitors described in the first aspect.

[0015] Compared with existing technologies, the technical solution of this patent achieves the following beneficial effects: 1. By using parameter presets and one-click selection, the product series switching time is reduced to the second level, completely eliminating the time spent on repeated manual adjustment and verification of parameters. This makes the impregnation production cycle more than 30% shorter than the traditional process, making it particularly suitable for production scenarios with rapid switching between multiple varieties.

[0016] 2. By solidifying and storing the optimal parameter combination verified by the process and executing it automatically, parameter deviations caused by human error or improper operation rhythm are completely avoided, ensuring the absolute consistency of process conditions for each batch of products. This significantly improves impregnation uniformity, reduces product parameter dispersion, and increases product qualification rate.

[0017] 3. The entire process is automated, and operators can start production simply through a user-friendly interface. This reduces reliance on operators' professional skills and experience, simplifies training, and reduces uncertainty caused by human intervention, thereby improving the reliability and safety of the production process.

[0018] 4. The scalable parameter database design allows for the addition and modification of process parameters at any time to adapt to new products without changing the hardware; at the same time, the system supports multiple immersion modes (such as negative pressure and alternating positive and negative pressure), realizing multi-purpose functionality, greatly enhancing the flexibility of the production line and the ability to respond quickly to different market demands, extending the service life of the equipment, and achieving a high return on investment.

[0019] 5. By integrating sensors (such as liquid level detection), automatic actuators (such as automatic locking), and intelligent control cores, closed-loop automation of the entire process from preparation and execution to completion has been achieved, which is a key process improvement for capacitor manufacturing to move towards industrial and intelligent manufacturing. Attached Figure Description

[0020] Figure 1 A flowchart of the automatic impregnation process for solid aluminum electrolytic capacitors provided in this embodiment of the invention; Figure 2 This is a schematic diagram of the automatic impregnation system provided in an embodiment of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Example 1: As Figure 1 As shown, an automatic impregnation process for solid aluminum electrolytic capacitors is provided. The automatic impregnation process in this embodiment includes the following steps: Parameter preset steps: Based on the impregnation process requirements of different product series, multiple parameter combinations are preset and stored in the impregnation machine control system (such as an industrial computer or programmable logic controller PLC). Each parameter combination includes at least the negative pressure value, impregnation time and pressure relief rate, and is uniquely associated with a product series identification code. Production selection steps: Enter or select the identification code corresponding to the product series to be processed through the operation interface; Automatic execution steps: The control system automatically calls the corresponding parameter combination according to the selected identification code, and controls the impregnation machine to sequentially execute the automatic impregnation process, including vacuuming, injecting and maintaining the impregnation liquid, and stable depressurization.

[0023] By pre-setting parameters, the system solidifies optimized parameter combinations for different series within the control system, integrating previously discrete and empirical parameters into a standardized instruction set uniquely associated with an identification code. This is then implemented through a production selection process, enabling one-click recall. From a process flow perspective, this solution replaces manual on-site judgment and adjustment with a standardized instruction flow of pre-setting and selection, fundamentally eliminating errors from manual parameter adjustment and achieving second-level completion of product series switching, significantly improving production efficiency and process consistency. It solves the problems of low efficiency, operational complexity, and parameter deviations caused by human error in traditional impregnation processes, which require frequent and tedious manual setting and adjustment of multiple core parameters such as negative pressure, duration, and rate for different product series.

[0024] In the parameter preset step, the preset parameter combination also includes the impregnation liquid level parameter; in the automatic execution step, the control system replenishes the impregnation liquid in real time based on feedback from the liquid level detection mechanism to maintain the preset liquid level. By maintaining the liquid level through preset and feedback, the uniformity of product immersion is ensured to remain constant.

[0025] The automatic execution steps specifically include: S1. Control the sealing of the impregnation tank and evacuate the vacuum according to the preset negative pressure value; S2. Once the set negative pressure is reached, the impregnation solution is automatically injected to the preset level. The preset soaking time is maintained, with real-time replenishment based on the liquid level detection feedback during this period. S3. After soaking, release the pressure steadily according to the preset pressure release rate. The pressure release rate is configured to avoid sudden pressure changes that could damage the internal structure of the product. S4. After the pressure relief is completed, perform the final actions of impregnating liquid reflux and material lifting.

[0026] This structured, cyclical process replaces manual, discrete operations, ensuring accurate execution and precise coordination of parameters at each process stage. This makes the entire impregnation cycle highly stable and controllable, avoiding issues related to human intervention and guaranteeing the integrity of the product's internal structure. It solves the problems of traditional processes where multiple steps, such as vacuuming, liquid injection, pressure holding, and pressure release, rely on manual monitoring and operation, resulting in discontinuous processes, unstable cycles, and susceptibility to internal structural damage due to improper operation rhythms (such as excessively rapid pressure release). It ensures the physical stability of the impregnation environment, significantly improving the consistency of product parameters and yield.

[0027] The automated impregnation process also includes a parameter adjustment step: adding, modifying, or deleting stored parameter combinations through the control system to adapt to the production needs of different product specifications. By designing an independent parameter adjustment step at the system software level, the parameter database becomes an extensible, editable, and open list. This soft-expansion structure allows for adaptation to new product specifications by simply adding or modifying a set of parameters in the database, without altering any mechanical equipment (such as the impregnation machine itself) or core control logic. This greatly enhances the flexibility and future adaptability of the production line and reduces upgrade costs.

[0028] The impregnation process modes defined by parameter combinations include negative pressure impregnation mode or alternating positive and negative pressure impregnation mode. The process mode itself is treated as a pre-set and callable high-level parameter. This means that the same hardware system can switch between different modes, such as negative pressure impregnation and alternating positive and negative pressure impregnation, by calling different parameter combinations. This design achieves multi-purpose functionality from a system compatibility perspective, broadening the application range of the equipment, meeting diverse production needs, and improving the return on investment. It solves the limitation of a single impregnation process mode (such as negative pressure only), which cannot meet the needs of different industries or high-end products for more complex impregnation processes (such as alternating positive and negative pressure), often requiring completely different equipment configurations.

[0029] This embodiment further improves upon the previous one by adding real-time online monitoring of key physical properties of the impregnation solution (such as viscosity, temperature, and concentration) during the automatic execution cycle, and feeding the monitoring data back to the control system. The control system incorporates an optimization algorithm that can dynamically fine-tune the currently executed parameter combinations (such as negative pressure and soaking time) based on real-time data and a preset target model, achieving an intelligent closed loop of perception-decision-optimization-execution. Specifically, online viscosity sensors, temperature sensors, and concentration detection modules are integrated into the injection pipeline or inside the impregnation tank to acquire the physical state of the impregnation solution in real time. The parameter database of the control system not only stores fixed parameter combinations but also associates with or incorporates a process optimization model. This model defines the correspondence between impregnation solution characteristics (viscosity, temperature, etc.) and ideal process parameters (such as optimal negative pressure and suitable soaking time). This model can be trained and generated based on historical production data.

[0030] Achieving dynamic optimization: After the production selection step, the system calls preset basic parameters. During the impregnation solution injection stage of the automated execution step, the monitoring module starts working. The control module inputs the real-time monitored impregnation solution characteristic data into the optimization model to calculate the parameter correction amount for the current batch of materials. The system then executes subsequent processes such as soaking and depressurization according to the corrected parameters (e.g., automatically extending the soaking time by 5% due to slightly higher viscosity, or fine-tuning the negative pressure value). This solves the problem that fixed parameters are not always optimal due to batch differences in impregnation solution raw materials and changes in ambient temperature, affecting product consistency. It also solves the shortcomings of traditional processes and ordinary automated processes that cannot compensate for variables in the production process in real time. It leaps from ensuring consistent execution of process parameters to ensuring consistent process effects (impregnation depth and uniformity), achieving a new level of product yield and performance consistency.

[0031] Example 2: As Figure 2 As shown, an automatic impregnation system is provided, including a hardware component and a software control component.

[0032] The hardware component centers on the impregnation machine, including various physical operating parts: the impregnation tank containing the product and impregnation liquid, the sealing cap and its automatic locking mechanism for sealing, the vacuum pump providing a vacuum environment, the liquid injection mechanism for adding and replenishing the impregnation liquid, the pressure relief valve for controlling the pressure release rate, and the material rack for carrying the capacitor products. An automatic locking mechanism driven by a control module is used, serializing its actions and integrating them into the automated process. This completely eliminates the uncertainty of manual locking, ensuring the reliability of the seal for each operation, further reducing manual intervention, and improving safety and the overall automation level. In addition, a liquid level detection mechanism is installed inside or on the tank wall to monitor the impregnation liquid level in the impregnation tank in real time; the control module controls the liquid injection mechanism based on the feedback signal from the liquid level detection mechanism to maintain the preset liquid level. The addition of the liquid level detection mechanism as a real-time feedback sensor, together with the control module and the liquid injection mechanism, forms a closed-loop control loop. This achieves dynamic and precise maintenance of the liquid level, ensuring the continuous stability of process conditions within the preset range, and providing key hardware support for achieving highly uniform impregnation.

[0033] The software control component is integrated within the control system. Its core is the control module (which can be a PLC, industrial computer, or embedded controller), connected to the selection input module, parameter database, and the impregnation machine's main body signals. It is used to call the corresponding parameter combination based on the identification code and drive the impregnation machine to automatically complete the impregnation operation based on this parameter combination. The parameter database stores impregnation process parameter combinations uniquely associated with different product series identification codes; the selection input module receives the product series identification code input by the user. The selection input module is integrated into the operation panel of the impregnation machine's main body, which includes at least one of physical buttons, a touchscreen, or a scanner. Integrating diverse selection input methods into an intuitive operation panel provides a flexible and convenient human-machine interface.

[0034] The system works as follows: The operator inputs production instructions (product identification codes) through the operation panel. After receiving the instructions, the control module retrieves the corresponding parameter formula from the parameter database. Subsequently, according to the formula program, the control module sends precise control signals to each actuator (vacuum pump, liquid injection mechanism, pressure relief valve, automatic locking mechanism, etc.) of the impregnation machine body, and collects feedback signals from sensors such as the liquid level detection mechanism in real time, forming a closed-loop control, thereby driving the physical equipment to accurately and automatically complete the entire impregnation process described in Example 1.

[0035] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An automated impregnation process for solid aluminum electrolytic capacitors, characterized in that, Includes the following steps: Parameter preset steps: Based on the impregnation process requirements of different product series, multiple parameter combinations are preset and stored in the impregnation machine control system. Each parameter combination includes at least negative pressure value, impregnation time and pressure relief rate, and is uniquely associated with a product series identification code. Production selection steps: Enter or select the identification code corresponding to the product series to be processed through the operation interface; Automatic execution steps: The control system automatically calls the corresponding parameter combination according to the selected identification code, and controls the impregnation machine to sequentially execute the automatic impregnation process, including vacuuming, injecting and maintaining the impregnation liquid, and stable depressurization.

2. The automatic impregnation process for solid aluminum electrolytic capacitors according to claim 1, characterized in that, In the parameter preset step, the preset parameter combination also includes the impregnation liquid level parameter; in the automatic execution step, the control system replenishes the impregnation liquid in real time according to the feedback from the liquid level detection mechanism to maintain the preset liquid level.

3. The automatic impregnation process for solid aluminum electrolytic capacitors according to claim 2, characterized in that, The automatic execution steps specifically include: S1. Control the sealing of the impregnation tank and evacuate the vacuum according to the preset negative pressure value; S2. Once the set negative pressure is reached, the impregnation solution is automatically injected to the preset level. The preset soaking time is maintained, with real-time replenishment based on the liquid level detection feedback during this period. S3. After soaking, release the pressure steadily according to the preset pressure release rate. The pressure release rate is configured to avoid sudden pressure changes that could damage the internal structure of the product. S4. After the pressure relief is completed, perform the final actions of impregnating liquid reflux and material lifting.

4. The automatic impregnation process for solid aluminum electrolytic capacitors according to any one of claims 1-3, characterized in that, It also includes parameter adjustment steps: adding, modifying or deleting stored parameter combinations through the control system to adapt to the production needs of products with different specifications.

5. The automatic impregnation process for solid aluminum electrolytic capacitors according to any one of claims 1-3, characterized in that, The impregnation process modes defined by the parameter combination include negative pressure impregnation mode or alternating positive and negative pressure impregnation mode.

6. An automatic impregnation system for implementing the automatic impregnation process according to any one of claims 1-5, characterized in that, include: The main body of the impregnation machine includes an impregnation tank, a sealing cover, a vacuum pump, a liquid injection mechanism, a pressure relief valve, and a material rack for carrying materials; A parameter database is used to store combinations of impregnation process parameters that are uniquely associated with identification codes for different product series. The selection input module is used to receive the product series identification code input by the user. The control module is connected to the selection input module, parameter database and impregnation machine main body signal. It is used to call the corresponding parameter combination according to the identification code and drive the impregnation machine main body to automatically complete the impregnation operation based on the parameter combination.

7. The automatic impregnation system according to claim 6, characterized in that, It also includes a liquid level detection mechanism for real-time monitoring of the liquid level in the impregnation tank; the control module controls the injection mechanism based on the feedback signal from the liquid level detection mechanism to maintain the preset liquid level.

8. The automatic impregnation system according to claim 6, characterized in that, The sealing cover is equipped with an automatic locking mechanism, which is controlled by the control module to lock and release.

9. The automatic impregnation system according to claim 6, characterized in that, The selection input module is integrated on the operation panel of the immersion machine body, and the operation panel includes at least one of physical buttons, a touch screen or a scanner.

10. A control system, characterized in that, It includes a memory and a processor, the memory storing a computer program, and the processor executing the computer program to implement the steps of the automatic impregnation process for the solid aluminum electrolytic capacitor according to any one of claims 1-5.

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