Intelligent preparation process of air conditioner mounting plate integrated with multifunctional structure

Abstract

The invention relates to the technical field of intelligent preparation of air conditioner mounting plates, discloses an intelligent preparation process of an air conditioner mounting plate integrated with a multifunctional structure, and aims at solving the problems that a traditional air conditioner mounting plate is discrete in function and depends on later assembly, so that the structural reliability is poor, and the integration degree is low. The process comprises the following steps: constructing a parameterized three-dimensional model integrating a structure supporting region, a conductive wiring channel region, a heat dissipation flow channel region and a sensor embedding cavity region; dynamically optimizing an additive manufacturing path based on multi-physics field simulation; on-line quality monitoring and self-adaptive finishing are carried out by combining confocal laser scanning and numerical control milling; and finally, a silver-nickel alloy plating layer and a hydrophobic wear-resistant ceramic coating are applied, and the information two-dimensional code is etched. According to the technical scheme, high integration of multiple functions, reliable combination of multiple material interfaces and controllable whole-process quality are achieved, the structural consistency of the mounting plate is remarkably improved, the service life of the mounting plate is remarkably prolonged, and the intelligent operation and maintenance supporting capacity of the mounting plate is remarkably improved.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of intelligent preparation of air conditioner mounting plates, in particular to an intelligent preparation process of an air conditioner mounting plate with an integrated multifunctional structure. BACKGROUND

[0002] With the accelerated development of the integration trend of intelligent household appliances and buildings, as a core indoor environment regulation device, the installation structure of an air conditioner is evolving from a single support function to integration and intelligence. Traditional air conditioner mounting plates mostly adopt standardized metal supports and only provide mechanical fixing functions, lacking collaborative design of multiple functions such as electrical connection, cable management, sensor integration and heat management, and being difficult to meet the comprehensive needs of space utilization efficiency, installation convenience and post-maintenance flexibility of modern smart home systems. Especially in high-density residential or prefabricated building scenarios, the installation interface needs to simultaneously bear multiple tasks such as structural support, signal transmission and environmental perception, which puts higher requirements on the structural integration and preparation process precision of the mounting plate.

[0003] However, the existing air conditioner mounting plate manufacturing process generally adopts a step-by-step stamping, welding and surface treatment process, and the functional modules are independently processed and manually assembled, resulting in overall structural redundancy, cumulative assembly errors and difficulty in precise positioning of functional units. At the same time, under the demand of multifunctional integration, the traditional plate material cannot simultaneously construct conductive paths, heat dissipation channels and embedded sensor cavities on a single base body, causing subsequent wiring complexity, increased risk of heat accumulation and decreased system reliability. In addition, the preparation process lacks collaborative regulation of material microstructure and functional areas, making the mounting plate prone to stress concentration, coating peeling or electrical contact failure in long-term service.

[0004] Therefore, there is an urgent need for an intelligent preparation process of an air conditioner mounting plate that can integrally form a multifunctional structure and has high precision and high reliability. SUMMARY

[0005] The purpose of the present application is to provide an intelligent preparation process of an air conditioner mounting plate with an integrated multifunctional structure, which can effectively solve the problems in the background art.

[0006] To achieve the above-mentioned purpose, the technical solution adopted by the present application is as follows:

[0007] An intelligent preparation process of an air conditioner mounting plate with an integrated multifunctional structure, comprising the following steps:

[0008] Step 1: Construct an integrated digital three-dimensional design model containing a structural support area, a conductive wiring channel area, a heat dissipation channel area and a sensor embedded cavity area, generate it based on the spatial constraints and multi-system interface requirements of the air conditioner outdoor unit installation interface using a parameterized modeling method, and define the material attribute mapping relationship of each functional area;

[0009] Step 2: Based on the performance requirements of each functional area in the three-dimensional model, combined with the multi-physical field simulation results of thermal stress, current density and mechanical bearing capacity, the laser energy input and scanning strategy are dynamically optimized to realize dense forming and directional regulation of grain orientation and residual stress;

[0010] Step 3: Using a multi-nozzle collaborative additive manufacturing system, different component metal powders are accurately delivered according to spatial coordinates on the same substrate to form high-strength aluminum alloy support areas, high-purity copper alloy conductive areas, aluminum-silicon-carbon composite material heat dissipation gradient layers, and invar alloy transition layers, and the cooling rate is adjusted through in-situ infrared temperature measurement closed loop;

[0011] Step 4: When the additive forming reaches the preset layer height, the work is paused, the micro temperature sensor, vibration detection module and wireless communication chip are placed into the corresponding cavity, local high-frequency induction heating is used to realize solid-phase diffusion connection of the ceramic base and the metal base material, and then the cladding layer is completed by continuous deposition;

[0012] Step 5: Real-time acquisition of surface topography data of each layer is realized by using a confocal laser scanner, and the data is compared layer by layer with the theoretical model to identify deviations and automatically trigger the numerical control milling unit for slight trimming until the accuracy requirements are met;

[0013] Step 6: The finished product is sequentially subjected to vacuum heat treatment, silver-nickel alloy electroplating of the conductive surface, spraying of the external hydrophobic wear-resistant ceramic coating, and laser etching of a two-dimensional code containing product information at a specified location.

[0014] Preferably, the parameterized modeling method in step 1 supports variable-driven adjustment of mounting hole spacing, wiring channel orientation and heat dissipation fin density, with a hole center distance tolerance of within ±0.1 mm, a minimum turning radius of the wiring channel set to 8 mm, and the height of the heat dissipation fins exponentially increasing along the heat flow direction with a maximum height of 12 mm.

[0015] Preferably, the boundary conditions used in the finite element analysis in step 2 include simulating the thermal deformation effect caused by an environmental temperature of 55 degrees Celsius in summer conditions, and the periodic vibration load of 150 Hz frequency when the air conditioner is running, the simulation grid division accuracy reaches 0.2 mm, the time step is set to 0.001 seconds, and the laser scanning speed is adaptively adjusted within the range of 300 mm / s to 1200 mm / s according to the curvature change.

[0016] Preferably, the powder feeding accuracy of the multi-nozzle collaborative additive manufacturing system in step 3 is ±0.5 mg / s, each nozzle is independently controlled to open and close and the flow rate, the material switching transition zone length is limited within 1.5 mm, the grain refining agent titanium boron element addition ratio is 0.15%, and the rotating flow of the metal liquid in the molten pool is promoted by the alternating magnetic field auxiliary device to promote the transformation of columnar crystals to equiaxed crystals.

[0017] Preferably, in step 4, the response frequency of the in-situ infrared temperature measurement system is 100 Hz, the temperature measurement range covers 300 Kelvin to 2000 Kelvin, the adjustment cycle of the temperature control closed loop is less than 50 milliseconds, the pressure loading range of the solid-phase diffusion connection is 10 MPa to 30 MPa, the heat preservation time is 60 seconds, and the shear strength of the connection interface is not less than 90% of the parent material.

[0018] Preferably, in step 5, the cofocus laser scanner has an axial resolution of 0.8 micrometers, a lateral resolution of 5 micrometers, a data acquisition frequency of 20 frames per second, a CNC milling unit equipped with a diamond-coated tool with a diameter of 2 millimeters, a maximum feed speed of 500 millimeters per minute, a single dressing depth of no more than 0.1 millimeters, and a dressing path generated by fitting a B-spline curve.

[0019] Preferably, in step 6, the heating rate of the vacuum heat treatment is 10 Kelvin / minute, the holding temperature is 320 degrees Celsius, the holding time is 90 minutes, the cooling method is segmented controlled-speed cooling with inert gas, the thickness of the silver-nickel alloy coating is 15 micrometers, the nickel content is 8%, the thickness of the ceramic coating is 30 micrometers, and the microhardness reaches HV 850 or above.

[0020] Preferably, the process further includes: ultrasonic cleaning and plasma activation treatment of the substrate before the start of additive manufacturing, wherein the cleaning medium is a mixture of deionized water and ethanol, the ultrasonic frequency is 40 kHz, the treatment time is 15 minutes, the plasma gas is a mixture of argon and oxygen, the power density is 2 W / cm², and the contact angle of the substrate surface is reduced to below 15 degrees after treatment.

[0021] Preferably, it also includes: establishing a full-process process database, recording the material batch number, equipment operating parameters, environmental temperature and humidity, quality inspection results and operator information for each manufacturing batch, with a data storage period of no less than 15 years, and supporting remote access and traceability analysis via an industrial Ethernet interface.

[0022] Preferably, it also includes: configuring an edge computing unit to collect and extract features of acoustic emission signals, molten pool radiation intensity and vibration spectrum in real time during the additive manufacturing process, using a pre-trained convolutional neural network model to identify early defect patterns, and issuing an early warning and suggesting a production halt for inspection when the identification confidence level is greater than 95%.

[0023] Preferably, the process is suitable for manufacturing mounting plates with a thickness of 3 mm to 8 mm, with a complete manufacturing cycle of a single piece controlled within 4 hours, achieving an IT7 level dimensional accuracy, a flatness error of less than 0.1 mm / m², and a repeatability accuracy of better than 0.03 mm for all functional interface positions.

[0024] Compared with the prior art, the beneficial effects achieved by the present invention are:

[0025] This invention fundamentally changes the limitations of traditional air conditioner mounting plates, which are characterized by discrete functions and reliance on post-assembly, by constructing a digital three-dimensional design model integrating structural support, electrical conduction, thermal management, and sensing. It achieves optimal spatial matching of multifunctional units. The additive manufacturing path planning method guided by multi-physics coupling simulation allows for dynamic adjustment of laser energy input and scanning trajectory based on local functional requirements, effectively suppressing the accumulation of thermal stress and the risk of deformation and cracking during the forming process of complex structures. Through the synchronous deposition technology of graded functional materials, a continuous transition of mechanical strength, electrical conductivity, and thermal expansion characteristics is achieved within a single component, significantly improving the reliability of multi-material interface bonding. The in-situ packaging process of embedded functional units ensures the long-term stability of electronic components such as sensors in high-temperature metal environments, avoiding contact loosening and sealing failure problems caused by traditional post-assembly methods. A full-process online monitoring and adaptive compensation mechanism ensures the quality controllability of each manufacturing stage, significantly reducing the need for manual intervention and the scrap rate. The resulting air conditioning mounting plate not only features high integration but also boasts excellent overall structural consistency and a long service life. It is particularly suitable for large-scale deployment scenarios in prefabricated buildings and smart home systems, providing a reliable data interface foundation for subsequent intelligent operation and maintenance of equipment. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall technical solution architecture of the present invention;

[0027] Figure 2 This is a schematic diagram of the core principle framework of the dynamic optimization of laser additive manufacturing path driven by multiphysics simulation in this invention;

[0028] Figure 3 This is a flowchart outlining the main stages of the integrated forming of multifunctional regions and the in-situ packaging of embedded sensing units in this invention.

[0029] Figure 4 This is a schematic diagram of the multi-level interaction relationship and data flow of the whole-process online monitoring, adaptive adjustment and quality traceability in this invention. Detailed Implementation

[0030] 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.

[0031] Example 1

[0032] Currently, with the accelerating trend of smart home appliances and building integration, air conditioning installation structures are evolving from single-function support towards integration and intelligence. Traditional air conditioning mounting plates mostly use standardized metal brackets, providing only mechanical fixation and lacking collaborative design for multiple functions such as electrical connection, cable management, sensor integration, and thermal management. This makes it difficult to meet the comprehensive requirements of modern smart home systems for space utilization efficiency, installation convenience, and post-maintenance flexibility. Especially in high-density residential or prefabricated building scenarios, the installation interface needs to simultaneously bear multiple tasks such as structural support, signal transmission, and environmental sensing, which places higher demands on the structural integration and manufacturing precision of the mounting plate. To address the above technical problems, this invention proposes to construct a digital three-dimensional design model integrating structural support, electrical conduction, thermal management, and sensor integration. Combined with multi-physics simulation-driven gradient material additive manufacturing, in-situ encapsulation of embedded sensing units, and a full-process online monitoring adaptive trimming mechanism, a high-precision forming of a multi-functional integrated structure is achieved and applied to an intelligent manufacturing process for an integrated multi-functional air conditioning mounting plate.

[0033] refer to Figure 1 The overall technical architecture of this invention includes a digital modeling module, a multiphysics simulation and optimization module, a multi-nozzle collaborative additive manufacturing system, an embedded functional unit in-situ packaging unit, an online monitoring and adaptive trimming unit, a post-processing and identification unit, and a full-process data traceability and edge intelligent analysis platform. The modules interact with each other and synchronize commands via industrial Ethernet and a real-time control bus, forming a closed-loop intelligent manufacturing system.

[0034] In the aforementioned intelligent manufacturing process for an integrated multi-functional air conditioner mounting plate, step 1 involves constructing an integrated digital three-dimensional design model comprising a structural support area, a conductive wiring channel area, a heat dissipation channel area, and a sensor embedded cavity area. This model is generated using a parametric modeling method based on the spatial constraints of the air conditioner outdoor unit installation interface and the requirements of multiple system interfaces, and the material property mapping relationships for each functional area are defined. Specifically, step 1 first extracts spatial boundary conditions based on the installation flange dimensions, wall embedded parts locations, and pipeline routing of the target air conditioner outdoor unit model, establishing an assembly constraint envelope containing X, Y, and Z coordinate systems. Within this envelope, the structural support area is defined as the core skeleton bearing the main static and dynamic loads. Its topology is generated into a lightweight truss structure using a variable density topology optimization algorithm. The conductive wiring channel area is embedded within the support area along a non-load-bearing path, forming a closed wire channel to accommodate power and signal lines and avoid electromagnetic interference. The heat dissipation channel area is located near the compressor heat source side and consists of densely arranged microchannels and external heat dissipation fins, forming a forced convection heat dissipation path. The sensor embedded cavity area is distributed at vibration-sensitive points and key temperature monitoring points. The cavity shape is precisely matched to the shape of the micro-sensor, and lead holes and potting space are reserved. The parametric modeling method allows for dynamic adjustment of the mounting hole spacing, wiring channel direction, and heat dissipation fin density through a variable-driven mechanism. The hole center distance tolerance is controlled within ±0.1 mm to ensure high-precision docking with wall anchors. The minimum turning radius of the wiring channel is set to 8 mm to meet the engineering requirements of the bending radius of high-purity copper wires. The height of the heat dissipation fins increases exponentially along the heat flow direction, with a maximum height of 12 mm, to enhance the heat dissipation capacity of the downstream area. Each functional region is assigned an independent material property label in the model, including elastic modulus, thermal conductivity, electrical conductivity, and coefficient of thermal expansion, providing input for subsequent multiphysics simulations.

[0035] In the aforementioned intelligent manufacturing process for an integrated multifunctional air conditioner mounting plate, step 2 dynamically optimizes the laser energy input and scanning strategy based on the performance requirements of each functional area in the three-dimensional model, combined with the multiphysics simulation results of thermal stress, current density, and mechanical load-bearing capacity, to achieve dense forming and directional control of grain orientation and residual stress. Specifically, step 2 imports the three-dimensional model generated in step 1 into a multiphysics coupled simulation platform, applying the thermal deformation effect caused by an ambient temperature of 55 degrees Celsius under summer conditions, and the periodic vibration load at a frequency of 150 Hz during air conditioner operation as boundary conditions. The simulation mesh is divided with an accuracy of 0.2 mm, and the time step is set to 0.001 seconds to capture transient thermo-mechanical coupling responses. By solving the coupled system of the heat conduction equation, structural dynamics equation, and electromagnetic field equation, the temperature field, stress field, and current density distribution of each region under service conditions are obtained. Based on simulation results, a low scanning speed and high overlap strategy is adopted for high stress concentration areas (such as hole edges and corners) to increase the residence time of the molten pool and promote stress relaxation. For high current density areas (conductive channels), a high energy density and unidirectional scanning strategy is adopted to reduce the number of grain boundaries and improve conductivity continuity. For heat dissipation channels, a combination of spiral filling and high scanning speed is used to form fine equiaxed grain structures and enhance heat diffusion capabilities. The laser scanning speed is adaptively adjusted within the range of 300 mm / s to 1200 mm / s according to curvature changes. In areas with a curvature radius less than 5 mm, the speed is automatically reduced to 300 mm / s, while in flat areas it can be increased to 1200 mm / s, thereby improving manufacturing efficiency while ensuring forming quality. The output of this dynamic optimization process is a G-code instruction set containing layer-by-layer laser power, scanning speed, scanning spacing, and scanning direction, which directly drives the additive manufacturing equipment to execute.

[0036] In the aforementioned intelligent manufacturing process for an integrated multifunctional air conditioner mounting plate, step 3 utilizes a multi-nozzle collaborative additive manufacturing system to precisely deliver metal powders of different compositions onto the same substrate according to spatial coordinates. This forms a high-strength aluminum alloy support area, a high-purity copper alloy conductive area, an aluminum-silicon-carbon composite heat dissipation gradient layer, and an Invar alloy transition layer, respectively. The cooling rate is adjusted via in-situ infrared temperature measurement closed-loop control. Specifically, the multi-nozzle collaborative additive manufacturing system used in step 3 is equipped with four independent powder delivery nozzles, respectively loaded with 7075 high-strength aluminum alloy powder, C10200 high-purity copper alloy powder, Al-SiC composite material powder, and Fe-36Ni Invar alloy powder. Each nozzle is controlled by a piezoelectric ceramic actuator, with a powder delivery accuracy of ±0.5 mg / s, ensuring the stability of material delivery. During the deposition process, the CNC system switches and activates the corresponding nozzles in real time according to the G-code instructions generated in step 2, and controls the powder flow rate to synchronize with the laser focus position. In the interface region between different materials, the system automatically inserts a transition layer deposition subroutine: for example, between the aluminum alloy support region and the copper alloy conductive region, a 0.3 mm thick Invar alloy transition layer is first deposited to mitigate the difference in thermal expansion coefficients between the two (approximately 23 × 10⁻⁻⁴ for aluminum alloy). 6 / Kelvin, copper alloy, approximately 17×10⁻ 6 / Kelvin, Invar alloy approx. 1.2 × 10⁻ 6 Interfacial stress caused by Kelvin (K / K). The length of the material switching transition zone is limited to within 1.5 mm, and seamless connection is achieved by precisely controlling the nozzle switching timing and laser scanning path. To refine the grain structure, 0.15% titanium boron grain refiner is premixed in all metal powders, precipitating TiB2 heterogeneous nucleation cores during the solidification process of the molten pool. In addition, the system integrates an alternating magnetic field auxiliary device to generate a rotating magnetic field with a frequency of 50 Hz and an intensity of 0.5 Tesla, which causes forced convection of the molten metal in the pool, breaks the growth direction of columnar crystals, promotes the formation of equiaxed crystals, and thus improves the isotropy and mechanical properties of the material. The in-situ infrared temperature measurement system monitors the temperature of the cooling zone 5 mm behind the molten pool in real time, with a response frequency of 100 Hz and a temperature measurement range covering 300 Kelvin to 2000 Kelvin. The data is fed back to the cooling control system, and the local cooling rate is closed-loop adjusted by adjusting the flow rate and pressure of the inert gas nozzle. The typical cooling rate is controlled between 10³ and 10⁻⁶ Kelvin. 4 Kelvin / second to suppress the precipitation of harmful phases.

[0037] In the aforementioned intelligent manufacturing process for an integrated multifunctional air conditioner mounting plate, step 4 involves pausing the additive manufacturing process when the material reaches a preset layer height. A micro temperature sensor, vibration detection module, and wireless communication chip are then placed into the corresponding cavity. Localized high-frequency induction heating is used to achieve solid-phase diffusion bonding between the ceramic substrate and the metal base material. Subsequently, deposition continues to complete the cladding layer. Specifically, in step 4, when the forming height reaches 0.5 mm above the bottom of the sensor embedded in the cavity, the system automatically pauses laser deposition. A robotic arm retrieves the pre-calibrated micro temperature sensor (model PT1000), MEMS vibration detection module (range ±50g), and low-power Bluetooth 5.0 wireless communication chip from a clean storage chamber and precisely places them into the corresponding cavity. Both the sensor and chip have integrated alumina ceramic substrates at their bottoms, with their thermal expansion coefficients designed to match the metal base material. Subsequently, a high-frequency induction coil is moved above the cavity, and an alternating magnetic field with a frequency of 300 kHz and a power of 2 kW is applied, generating eddy current heating at the ceramic-metal interface, causing the local temperature to rapidly rise to 850 degrees Celsius. Simultaneously, a pneumatic loading device applies pressures of 10 to 30 MPa for 60 seconds, promoting solid-phase diffusion between metal atoms and the ceramic interface to form a metallurgical bond. An in-situ infrared temperature measurement system continuously monitors the temperature of the connection area with an adjustment cycle of less than 50 milliseconds, ensuring temperature fluctuations do not exceed ±10 degrees Celsius. After connection, the system verifies that the shear strength of the connection interface is not less than 90% of the base material. Additive manufacturing then resumes, continuing to deposit the overlay metal layer to completely encapsulate and seal the electronic components, leaving only the antenna window and lead outlet. This in-situ packaging process avoids damage to electronic components caused by high-temperature overall heat treatment, ensuring long-term service reliability.

[0038] In the aforementioned intelligent manufacturing process for an integrated multifunctional air conditioning mounting plate, step 5 involves using a confocal laser scanner to collect surface morphology data for each layer in real time. This data is compared layer by layer with the theoretical model to identify deviations and automatically trigger a CNC milling unit for micro-adjustment until the accuracy requirements are met. Specifically, after each deposition layer is completed, the confocal laser scanner is activated in step 5. Its axial resolution is 0.8 micrometers, its lateral resolution is 5 micrometers, and its data acquisition frequency is 20 frames per second, allowing for the acquisition of point clouds across the entire plate surface within 30 seconds. After registration, the collected data is compared with the theoretical model from step 1 using Hausdorff distance calculation to identify areas with out-of-tolerance. When a local height deviation exceeds ±0.05 mm or a flatness error exceeds 0.1 mm / m², the system automatically generates an adjustment command, driving the five-axis CNC milling unit to intervene. This unit is equipped with a 2 mm diameter diamond-coated tool, a maximum feed rate of 500 mm / min, and a single adjustment depth not exceeding 0.1 mm to avoid introducing new thermal stress. The dressing path is generated by fitting a B-spline curve to ensure a smooth trajectory and reduce tool vibration. After dressing, the path is scanned again for verification, forming a closed loop of "deposition-scanning-dressing" until all functional areas meet the IT7 level dimensional accuracy and 0.03 mm repeatability requirements.

[0039] In the aforementioned intelligent manufacturing process for an integrated multifunctional air conditioner mounting plate, step 6 involves sequentially performing vacuum heat treatment, silver-nickel alloy electroplating on the conductive surface, and spraying an external hydrophobic and wear-resistant ceramic coating on the finished product. A QR code containing product information is then laser-etched at a designated location. Specifically, step 6 first places the formed part in a vacuum heat treatment furnace, evacuates it to 10⁻³ Pa, and heats it to 320 degrees Celsius at a rate of 10 Kelvin / min, holding it at that temperature for 90 minutes to eliminate residual stress and promote solid solution strengthening. Subsequently, inert gas is used for segmented controlled-rate cooling: the first stage cools to 200 degrees Celsius at 50 Kelvin / min, and the second stage cools to room temperature at 20 Kelvin / min to prevent microcracks caused by rapid cooling. After heat treatment, the exposed end faces of the conductive wiring channels are electroplated with a silver-nickel alloy. The plating solution consists of potassium silver cyanide and nickel sulfate, the current density is 3 amperes / dm², and the plating thickness is 15 micrometers, with a nickel content of 8% to balance conductivity and oxidation resistance. Next, the outer surface of the mounting plate is plasma-sprayed with Al2O3-TiO2 composite ceramic powder. The coating thickness is 30 micrometers, the microhardness reaches HV 850 or higher, and it has a contact angle of over 110 degrees, achieving both hydrophobicity and wear resistance. Finally, in designated non-functional areas, a 20×20 pixel QR code is etched using a UV picosecond laser. The code contains the batch number, material information, manufacturing date, and unique serial number, facilitating traceability throughout the entire lifecycle.

[0040] In addition, the substrate underwent ultrasonic cleaning and plasma activation treatment before additive manufacturing began. The substrate was made of Q235 carbon steel with a thickness of 5 mm. The cleaning medium was a solution of deionized water and ethanol mixed in a volume ratio of 3:1, the ultrasonic frequency was 40 kHz, and the treatment time was 15 minutes to remove grease and micro-particulate contaminants. Subsequently, it was transferred to a plasma treatment chamber, where a gas mixture of argon and oxygen in a flow rate ratio of 4:1 was introduced at a power density of 2 W / cm² for 5 minutes. This process formed a hydroxylated active layer on the substrate surface, reducing the surface contact angle to below 15 degrees and significantly improving the wettability and bonding strength of the first layer of metal powder.

[0041] Furthermore, the system establishes a full-process database, recording the material batch number, equipment operating parameters (including laser power, scanning speed, powder feed rate, cooling air pressure, etc.), environmental temperature and humidity, quality inspection results (including dimensional reports, conductivity tests, shear strength data), and operator information for each manufacturing batch. All data is uploaded to the cloud server in real time via the OPC UA protocol, with a data storage period of no less than 15 years. It supports remote access and traceability analysis via an industrial Ethernet interface, meeting the requirements of the ISO 9001 quality management system.

[0042] Furthermore, the system is equipped with an edge computing unit deployed within the industrial gateway at the manufacturing site. This unit collects acoustic emission signals (sampling rate 1 MHz), molten pool radiation intensity (wavelength range 400 to 1100 nm), and equipment vibration spectrum (frequency range 0 to 10 kHz) in real time during the additive manufacturing process. A pre-trained convolutional neural network (CNN) model is used to extract and fuse features from the multi-source signals, identifying early defect patterns such as spheroidization, lack of fusion, and cracks. When the identification confidence level exceeds 95%, the system automatically issues an audible and visual warning and recommends suspending production for inspection to prevent the accumulation of defects that could lead to the scrapping of the entire part.

[0043] The air conditioner mounting plate prepared in this embodiment is 6 mm thick, the complete preparation cycle for a single piece is 3 hours and 45 minutes, the finished product dimensional accuracy reaches IT7 level, the flatness error is 0.08 mm / square meter, and the repeatability of all functional interface positions is 0.025 mm, which fully meets the installation requirements of high-density prefabricated buildings.

[0044] refer to Figure 2 The multiphysics simulation-driven dynamic optimization process for laser additive manufacturing paths is as follows: the input consists of air conditioner outdoor unit interface constraints and functional requirements; a performance mapping map is obtained through multiphysics simulation; then, a spatially variable process parameter field is generated; and finally, adaptive G-code is output. This framework ensures a direct correlation between the manufacturing process and product performance.

[0045] refer to Figure 3The main stages of the integrated molding of multi-functional regions and in-situ packaging of embedded sensing units include: A) gradient material partitioning deposition; B) cavity molding to a predetermined height; C) precise placement of electronic components; D) local induction heating solid-phase bonding; and E) topcoat sealing. Each stage is strictly controlled to ensure functional integrity.

[0046] refer to Figure 4 The multi-level interactive relationship of full-process online monitoring, adaptive adjustment and quality traceability is manifested as follows: the bottom layer is the sensor layer (confocal scanner, infrared temperature measurement, acoustic emission, etc.), the middle layer is the control execution layer (CNC milling, laser, powder feeding system), and the upper layer is the data management layer (process database, edge AI, remote traceability platform). The three layers are closely coupled through real-time data bus and event-driven mechanism to form a closed loop of intelligent manufacturing that is self-sensing, self-decision-making and self-execution.

[0047] Example 2

[0048] Based on Example 1, a modified fabrication scheme for air conditioning mounting plates suitable for extreme climate regions is considered. This scheme makes targeted adjustments to the material system and heat treatment process to address the alternating low winter temperatures (-30 degrees Celsius) and high summer temperatures (60 degrees Celsius).

[0049] In the digital modeling of step 1, the structural support area uses Inconel 718 nickel-based high-temperature alloy instead of 7075 aluminum alloy to improve low-temperature toughness and high-temperature strength; the conductive wiring channel area still uses C10200 copper alloy, but adds a double-layer shielding structure, with copper as the inner layer and permalloy as the outer layer, to suppress electromagnetic performance drift under extreme temperatures; the heat dissipation channel area uses copper-graphene composite material, and the thermal conductivity is increased to 450 W / m·Kelvin; the sensor embedding cavity area is expanded by 20% to accommodate additional humidity and frost sensors.

[0050] In the multiphysics simulation of step 2, the boundary conditions were expanded to a full thermal cycle load from -30°C to 60°C, and the time step was shortened to 0.0005 seconds to capture the material phase transformation process. The laser scanning strategy employed preheating scanning (preheating temperature 200°C) in the low-temperature region to prevent cold cracking; and intermittent scanning in the high-temperature region to avoid overheating.

[0051] In the additive manufacturing step 3, a fifth nozzle is added to the multi-nozzle system for feeding Inconel 718 powder. Powder feeding accuracy is improved to ±0.3 mg / s, and the material switching transition zone length is shortened to 1.0 mm. The alternating magnetic field strength is increased to 0.8 Tesla to handle the high-viscosity nickel-based alloy molten pool.

[0052] In the post-processing of step 6, the vacuum heat treatment holding temperature was increased to 720 degrees Celsius, the holding time was extended to 120 minutes, and an aging treatment step (holding at 620 degrees Celsius for 8 hours) was added to precipitate the γ' strengthening phase. The nickel content in the silver-nickel alloy plating was increased to 12% to enhance resistance to sulfide corrosion. The ceramic coating was changed to a ZrO2-Y2O3 thermal barrier coating, and the thickness was increased to 50 micrometers to reduce the temperature fluctuation of the substrate.

[0053] The mounting plate prepared by this modified design showed no brittle fracture in the -40°C impact test and its conductivity decreased by less than 3% after aging at 80°C for 1000 hours, making it suitable for harsh application environments in the border areas between cold and tropical zones.

[0054] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

[0055] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An integrated multifunctional structure air conditioner mounting plate intelligent manufacturing process, characterized by: The method comprises the following specific steps: Step 1: constructing an integrated digital three-dimensional design model comprising a structural support area, an electrically conductive wiring channel area, a heat dissipation flow channel area, and a sensor embedding cavity area, generating the model based on the spatial constraints of the air conditioner outdoor unit installation interface and the multi-system interface requirements, and defining the material property mapping relationship of each functional area; Step 2: dynamically optimizing the laser energy input and scanning strategy according to the performance requirements of each functional area in the three-dimensional model, combining the results of multi-physical field simulation of thermal stress, current density, and mechanical bearing capacity, to realize dense forming and directional regulation of grain orientation and residual stress; Step 3: using a multi-nozzle collaborative additive manufacturing system to accurately deliver different component metal powders on the same substrate according to spatial coordinates, respectively forming a high-strength aluminum alloy support area, a high-purity copper alloy conductive area, an aluminum-silicon-carbon composite material heat dissipation gradient layer, and an invar alloy transition layer, and adjusting the cooling rate through in-situ infrared temperature measurement closed loop; Step 4: pausing the work when the additive forming reaches the preset layer height, placing a miniature temperature sensor, a vibration detection module, and a wireless communication chip into the corresponding cavity, achieving solid-phase diffusion bonding of the ceramic base and the metal base material by local high-frequency induction heating, and then continuing to deposit the cladding layer; Step 5: using a confocal laser scanner to collect surface topography data in real time, comparing it with the theoretical model layer by layer, identifying deviations and automatically triggering a numerical control milling unit for minor trimming until the accuracy requirements are met; Step 6: sequentially performing vacuum heat treatment, silver-nickel alloy electroplating of the conductive surface, spraying of a hydrophobic and wear-resistant ceramic coating on the outside, and laser etching of a two-dimensional code containing product information at a specified location.

2. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: The parameterized modeling method in step 1 supports variable-driven adjustment of mounting hole spacing, wiring channel orientation, and heat dissipation fin density, with a hole center distance tolerance of within ±0.1 mm, a minimum turning radius of the wiring channel set to 8 mm, and an exponential increasing distribution of the heat dissipation fin height along the heat flow direction with a maximum height of 12 mm.

3. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: The boundary conditions used in the finite element analysis in step 2 include simulating the thermal deformation effect caused by an environmental temperature of 55 degrees Celsius in summer conditions and the periodic vibration load of 150 Hz frequency when the air conditioner is running, the simulation grid division accuracy is 0.2 mm, the time step is set to 0.001 seconds, and the laser scanning speed is adaptively adjusted within the range of 300 mm / s to 1200 mm / s according to the curvature variation.

4. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: The powder feeding accuracy of the multi-nozzle collaborative additive manufacturing system in step 3 is ±0.5 mg / s, each nozzle is independently controlled to open and close and to adjust the flow rate, the material switching transition zone length is limited within 1.5 mm, the grain refining agent titanium boron element addition ratio is 0.15%, and the rotating flow of the metal liquid in the molten pool is promoted by an alternating magnetic field auxiliary device to facilitate the transformation of columnar crystals to equiaxed crystals.

5. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: The response frequency of the in-situ infrared temperature measurement system in step 4 is 100 Hz, the temperature measurement range covers 300 K to 2000 K, the temperature control closed loop adjustment period is less than 50 ms, the pressure loading range of solid phase diffusion bonding is 10 MPa to 30 MPa, the holding time is 60 s, and the bonding interface shear strength is not less than 90% of the base material.

6. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: The axial resolution of the confocal laser scanner in step 5 is 0.8 microns, the lateral resolution is 5 microns, the data acquisition frequency is 20 frames per second, the numerical control milling unit is equipped with a diamond-coated tool with a diameter of 2 mm, the maximum feed speed is 500 mm / min, the single trimming depth is not more than 0.1 mm, and the trimming path is generated by B-spline curve fitting.

7. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: The heating rate of vacuum heat treatment in step 6 is 10 K / min, the holding temperature is 320℃, the holding time is 90 min, the cooling method adopts inert gas staged speed control cooling, the silver-nickel alloy coating thickness is 15 microns, the nickel content is 8%, the ceramic coating thickness is 30 microns, and the microhardness reaches more than HV 850.

8. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: The substrate is subjected to ultrasonic cleaning and plasma activation treatment before additive manufacturing, the cleaning medium is a mixture of deionized water and ethanol, the ultrasonic frequency is 40 kHz, the treatment time is 15 min, the plasma gas is a mixture of argon and oxygen, the power density is 2 W / cm2, and the substrate surface contact angle is reduced to below 15 degrees after treatment.

9. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: A full-process process database is established to record the material batch number, equipment operating parameters, environmental temperature and humidity, quality test results and operator information of each manufacturing batch, the data storage period is not less than 15 years, and remote access and traceability analysis are supported through an industrial Ethernet interface.

10. The intelligent manufacturing process of an integrated multifunctional structure air conditioner mounting plate according to claim 1, characterized in that: An edge computing unit is configured to collect and extract features of acoustic emission signals, molten pool radiation intensity and vibration spectrum in real time during additive manufacturing, and a pre-trained convolutional neural network model is used to identify early defect patterns, and when the recognition confidence is greater than 95%, an early warning is issued and production is suggested to be suspended for inspection.

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